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Platestream SC manual

1. 19 WHITE GND WHITE 19 CAPSTAN STEPPER 20 BLACK CUT STEP BLACK 20 804628 001 gt 21 BROWN CUT STEP BROWN 21 Ill 22 RED GND RED 22 23 ORANGE CUT RESET ORANGE 23 MARKER TRANS 1 24 YELLOW CUT RESET YELLOW 24 1 BLACK 803323 002 1 1 BLUE WH 25 GREEN GND GREEN 25 4 2 RD i 26 BLUE PLG OP BLUE 26 J 3 RED 3 3 GREEN ll 7 27 _VIOLET PLG OP VIOLET 27 z x x VI 28 GRAY GND GRAY 28 II uz J6 NU 29 WHITE STEP SYNC WHITE 29 zziz Sala a 1212 5 30 BLACK STEP SYNC BLACK 30 31 BROWN GND BROWN 3l fo 6 32 RED SPARE3 RED 32 L L L 33 ORANGE SPARE 3 ORANGE 33 34 YELLOW GND YELLOW 34 DECURL EXIT 1 JS 35 GREEN FD TR DIR GREEN 35 2 36 BLUE FD TR DIR BLUE 36 J2 3 gt 37 VIOLET GND VIOLET 37 4 38 GRAY SPARE 1 GRAY 38 EFFLUENT TANK LEVEL vi gt PROCESSOR J4 NU 39 WHITE SPARE 1 WHITE 39 NU 3 523200 001 CABLE 806306 002 40 BLACK GND BLACK 40 PS 806815 002 NU 41 BROWN SPAREO BROWN 41 SCHEMATIC PAGE 6 EA OND ORANGE 43 ORANGE GND ORANGE 43 80679 EM ORANCR 24 44 YELLOW EX DIR YELLOW 44 CUTTER ASSY 324V 45 GREEN EX DIR GREEN 45 1 rack 2 EAN DR WHITE 2 46 BLUE GND BLUE 46 WHITE 2 REPLENISHMENT TANK BLACK 3 47 VIOLET SPARE2 VIOLET 47 SHEAR CUTTER 1 BLACK 1 7 COOLING FAN 48 GRAY SPARE 2 GRAY 48 SENSORS
2. Printware Confidential O O PlateStream SC a SE d Platesetter ITEM 3 Printware ASSY IMAGER SC 808041 001 REVISION D Sheet 1 of 2 OD 5 D NN k NN CM a NN Printware N Za 5 2 mee A gt PI 8 V 4 e OR 2 NS 5 P NN NN Od dp NN XE 4 D A e gt z Y A I 2s xac ee 9 ASS Y IMAGER SC 808041 001 REVISI N D Sheet 2 of 2 Printware Confidential Find Number 001 003 005 006 010 011 012 013 014 015 016 017 018 020 022 023 031 039 040 041 042 043 044 049 050 051 052 053 054 070 072 073 079 080 084 085 086 087 088 090 091 092 Quantity Component Used NO N N KF KF NO m P3 n n2 yr N ON N mo omo A A Assembly Number 808044 001 Number 807590 001 822307 900297 001 803305 001 807350 001 804604 001 900229 002 900360 000 900928 002 901023 001 900871 008
3. WIRING DIAGRAM PlateStream SC ololese E EST E E Ee E ES ES Ea S sl 3 SF 21S AALS sss Lee Z COMM CODE E 700636 001 esae St 2 FIRST USED ON B A This document and the information it contains is the property of Printware Inc and may not be TO INTERF ACE PC A J1 2 SCHEM ATIC P AGE j reproduced copied disclosed to others or disposed of directly or indrectly without authoriza SCALE NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 3 f 6 proprietary and may not be used in any manner not consistent with the rights of Printware Inc ee o 2 3 4 5 6 al EAI Is tf Ka ES IS of A Sl II SI ISI I al ISI e e ex ees es en en lol en eo sf n n n Sq Sg Po ma mia mia mia mia On OF O O O9 O E M O E M O E M O E M O CABLE 807530 001 NEEEREBEEEREEENENEEERESENEREEEREEEREBSENEEE NER aeee sosoo gaza 3 S 2 5 2 sas szasz 8 She 213 S S S 218 2 2 2 31S S 218 2 a 2 31S a Pal ez S Ol ea Ol S cal el O Ola gt Ol S a al el O gt Ol al S Ol sl al al el SE S a
4. COMM CODE Size 700636 001 INSP VERSION REV FIRST USED ON B E A This document and the information it contains is the property of Printware Inc and may not be S C EM ATIC P AGE 2 reproduced copied disclosed to others or disposed of directly or indrectly without authoriza SCALE NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 2 f 6 proprietary and may not be used in any manner not consistent with the rights of Printware Inc ee o 1 3 4 5 6 CABLE 807150 002 1 BROWN NC V 1 2 RED PRN GND 20 CABLE 3 ORANGE NC 2 803319 002 807117 004 4 YELLOW PRN GND 21 5 GREEN NC 3 RED V 5V 1 6 BLUE PRN GND 22 POWER SUPPLY BLACK GND 2 7 VIOLET NC 4 DRAWER RED 45V 3 8 GRAY PRN GND 23 BLACK GND 4 9 WHITE NC 5 807046 001 YELLOW 12V 5 CONTROLLER PCA 10 BLACK PRN GND 24 BLACK GND 6 11 BROWN PIX ENBL 6 BLUE 12V 7 522980 001 IR 12 RED PIX ENBL 25 BLACK GND 8 522980 002 RED 13 ORANGE PIX CLK 7 ORANGE 24V 9 14 YELLOW PIX CLK 26 J4 BLACK GND 10 15 GREEN PRN D0 8 16 BLUE PRN D0 27 17 VIOLET PRN DI 9 18 GRAY PRN DI 28 19 WHITE PRN D2 10 INTERLOCK PWR 1 20 BLACK PRN D2 20 TO RIP INTERLOCK ASSY 12V 2 21 BROWN PRN 11 NC 3 22 RED PRN D3 30 806307 002 23 ORANGE PRN_D4 12 24 YELLOW PRN D4 3 25 GREEN PRN D5 13 26 BL
5. menu INSTALLATION GUIDE Physical Calibration Overview Follow the procedures detailed in this section to calibrate Platesetter for production at the customer site Be sure to follow these procedures in the order presented Before performing these calibration procedures make sure the Platesetter is in its final location and that it has been properly leveled Once set these calibrations should not have to be repeated unless a problem 15 noticed If any of the orange torque seals on the screws are broken the Platesetter warranty is void Cutter Skew Plates must be cut square in order to avoid problems with image position straightness and registration when mounted on the press The cutter will pivot at the front of the Imager and can be moved toward or away from the capstan roller at the rear of the unit 1 To determine plate cut squareness print either a grid pattern or a solid pattern from the RIP 2 Once the plate has been imaged and processed measure and compare the diagonal distance of opposite corners of the cut plate see Figure I 5 3 If the plate is square within specification skip the remaining steps and go on to the Transport Skew procedure Leading Edge UJ 4 Remove the back cover from the Platesetter Locate the cutter bracket and note the current position of the cutter a reference line will be inscribed on the bracket at the factory 5 Loosen the two 9 64 Allen cap screws e If angle A
6. 1 2 3 4 5 6 Cote eom JC Platesetter Illustrated Parts Last Ploteftreany gc 1 r Printuore LEADERS IN COMPUTER TO PLATE 700635 001 Rev A Assembly Number 808040 00X PLATESTREAM SC Revision 01 Find Quantity Component Component Number Used Number Description Parts List Page 1 of 1 001 1 808041 001 ASSY IMAGER SC 002 1 807245 001 ASSY MARKER 13 IR SC 002 1 807245 003 ASSY MARKER 13 RED SC 003 1 808046 001 ASS Y POWER SUPPLY SC DOMESTIC ORIGINAL 003 1 808050 001 ASSY POWER SUPPLY SC DOMESTIC DASH 4 001 002 Printware Confidential Printware ASSY PLATESTREAM SC 808040 00X REVISION A Sheet of 1 Find Number 002 003 004 005 006 007 008 009 012 014 015 020 044 049 052 054 057 058 059 060 061 062 063 064 065 066 067 068 071 076 077 078 079 080 081 084 087 090 116 117 121 123 Quantity Component Used ON OO a Lm Lm L WO O Aa R N N A A Q E 0 GO rn DM Assembly Number 808041 001 Number 901273 003 807601 001 807601 002 807601 003 807601 004 807602 001 807607 001 900823 002 900235 002 900047 000 900445 006 90127
7. Find Number 001 002 003 005 006 007 008 009 011 012 013 014 015 016 017 018 019 020 021 022 024 025 026 027 028 029 030 031 032 033 038 039 040 041 042 043 044 045 047 048 049 050 Assembly Number 806926 002 ASSY PUNCH SC PINBAR Quantity Component Used 1 N N po UJ N bh e e N Be N m NO m N C WoO na e OC Number 807415 002 901051 005 807460 002 901051 008 900940 003 900940 004 900940 005 900289 003 901053 001 901052 003 807301 001 807616 001 807617 001 807615 001 900235 041 807661 001 901283 001 806935 001 806934 001 807677 001 900236 002 900610 003 807660 001 806936 001 900319 004 807614 002 900570 007 807664 001 900157 008 901187 003 900160 004 900160 005 90065 1 022 90065 1 020 900047 000 900445 006 900445 007 900236 008 900235 040 900233 003 900233 001 900288 006 Revision T Component Description ASS Y COMPRESSOR MODIFIED FITTING TUBE QUICK STRAIGHT ASSY PUNCH PINBAR FITTING TUBE QUICK STRAIGHT TUBING POLYURETHANE RED EA FT TUBING POLYURETHANE ORANGE TUBING POLYURETHANE GREEN BUSHING GROMMET MUFFLER PNEUMATIC SOLENOID AIR VALVE ASSY CABLE SOLENOID PLATE FRONT DEFLECTOR PLATE BACK DEFLECTOR TROUGH PUNCH SCREW SHC 8 32 X 1 1 4 TRAY PUNCH HANDLE PLASTIC TAPERED BRACKET PUNCH MOUNTING NON OPERATOR SIDE BRACKET PUNCH MOUNTING OPERATOR SIDE ASSY PUNCH UPPER GUIDE SCREW SOCKET HEAD SHO
8. 1 Open the top cover and raise the marker assembly Remove media if present 2 Remove both snap rings from end of the rollers 3 Slide the roller toward the rear of the platesetter and remove 4 Install the new rollers in reverse order Removing the Pinch Rollers Left and Right See Figure S2 2 1 Open the top cover and raise the marker Remove the front and rear panel 2 Remove the E clips spacers if any and bushings from each end of the pinch roller shaft 3 Remove the spring loaded tensioner from each end of the roller shaft by removing the hex nut 4 Access the shutter from the top of the Platesetter Loosen the four screws on the shutter to access the roller Remove the roller by sliding the roller towards the rear of the frame until it clears the frame 5 Install the new roller in reverse order Lower marker assembly and close the top cover 21 SERVICE MANUAL Removing the Capstan roller and Capstan Drive Assembly See Figure S2 2 S3 1 Marker Lever Marker Capstan Drive Motor Figure S3 1 Location of the Capstan Drive Motor 1 Open the top cover and raise the marker Remove the front and rear panels 2 Remove the pinch rollers Refer to the previous procedure 3 Access the capstan drive assembly from the front of the Platesetter Disconnect the cable from the capstan drive assembly Remove the capstan drive assembly by re
9. Busy Imager communicating with the RIP On Off Line Backing Up Backing up leader of plate from cutter to start of image point On Off Line Marker Hold Marker getting ready to image On Off Line Imaging Imaging current plate On Off Line Image Leader Imaging leader of next plate On Off Line Advancing Advancing plate to cutter On Off Line Cutting Cutting plate On Off Line Punching Punching Plate On Off Line Transporting Moving media out of the imager On Off Line Loading Loading media On Off Line Feeding Moving media into or through the imager CONTROL PANEL On Off Line Ready Pause 0 5 sec pause between plates On Off Line Ready Trans Imager ready to start imaging plate s still in imager On Off Line Ready Proc Imager ready to start imaging plate s in processor only A0075 Approximate number of feet of media left on input spool A if length of media on the spool was entered when the spool was loaded 2400 dpi Current resolution dots per inch NO MEDIA No media detected at sensor closest to input spool LOW WORKING Either or both of the processor working tanks are low on chemistry INTERLOCK OPEN The marker is in the raised position Line 8 LOW PROC TEMP The processor activator bach is not up to specified temperature HIGH EFF The effluent tank is full LOW REPL Either or both of the replenisher tanks are empty CONTROL
10. ESC or OFF key 5 Miniplate Cut Length Only with Miniplate option installed Cuts the plate if accumulated Miniplate length exceeds this value Values are integer inches e g 12 13 14 15 16 17 or 18 The 18 setting cuts all plates greater than 17 5 The minimum cut length is 12 The maxi mum cut length is 18 6 Miniplate Backup Enables calibration or elimination of the gap between jobs in Miniplate mode see Physical Calibration in the INSTALLATION GUIDE 7 Guide B Turns the Guide B sensor On OFF The sensor should be ON to detect jams unless the sensor is damaged 8 Punch Only if punch option installed turns the punch on and off 2 10 CONTROL PANEL Run Hardware Menu Run Hardware ESC to exit 1 Transport Motor OFF 5 Reset Proc 2 Cut Plate 6 Start Proc 3 Shutter Close 7 Prime Pump 4 Punch Plate ON ESC OFF ENTER 1 Transport motor Turns on or off the capstan motor 2 Cut Plate Cycles the cutter 3 Shutter Opens and closes the shutter 4 Punch Plate Cycles the Punch 5 Reset Proc Stops the processor and resets all of the counters 6 Start Proc Starts the processor to test for functionality of this section 7 Prime pump Turns on the processor pump for approximately five minutes 2 11 CONTROL PANEL Calibrate Menu Calibrate ESC to exit 1 Calibrate Transport Calibrate Marker zu
11. Media not loaded far enough messages bend the No Media switch lever back toward the left of the machine slightly to increase its sensitivity 32 SERVICE MANUAL GENERAL IMAGER PROBLEMS cont Imaging seems to First plates do take longer than plates immediately after the first take too long plate General guidelines for first plate total times are as follows Resolution No punch With Punch 2400 DPI 3 min 3 min 30 sec 53 MEDIA JAMS Imager Module Media will not load past Guide B Media gets dog eared before going into cutter Media buckles in feed section Guide A Media jams in Guide B machine produces 3 5 media strips Media jams in cutter 0D S SERVICE MANUAL If the corner of the media is being dog eared before going into cutter inspect shutter for prob lems Replace Teflon tape non Shutter assembly Verify that the shutter plate isn t hitting the capstan roller To adjust loosen screws on the outside of the transport on the operator and non operator side Adjust the shutter plate to 1 32 to 1 16 0 8 to 1 6 mm from the capstan roller Adjust the moveable shutter arm farther out If the media is stubbing on the shutter replace the Teflon tape on the shutter assembly Verify that edge guides are aligned with spool see Operator Guide for loading procedure Verify that feed rollers are turning Check that marker transport belts aren t slipping Adjust Marker Transport
12. SERVICE MANUAL NOTE There are no procedures for replacing the SOS and SOT sensors The SOS and SOT sensors are part of the marker assembly and are not replaced separately Grounding Controller PCA Connector Marker Capstan Roller Cutter Optional Punch k Media Input Spool Stepper Interface PCA PCA Figure S4 1 Location of the PCAs viewed from back of imager Controller PCA Location and Function The controller PCA is attached to the top of the marker See Figure S4 1 Controller PCA elec tronics perform the following functions econtrol data transmission from RIP to Platesetter econtrol laser intensity 27 SERVICE MANUAL econtrol laser data rate emonitor all sensors econtrol galvo econtrol motors The non volatile SRAM memory of the controller PCA stores the total plate count the image quality settings specified using the Manual Setup menu on the control panel for both polyester and paper plate material the image position settings and the calibration settings Voltages Supplied to Controller PCA 5 VDC to power all integrated logic chips 24 VDC 12 VDC 12 VDC Connector Assignments J1 Laser power and control J2 Not used J3 To RIP J5 Not used J6 Power J7 Laser safety interlock switch JS Imager RIP Interface J9 Interface PCA control panel communication cable J11
13. 1 Turn the Platesetter off wait 30 seconds an turn the Platesetter back on and walt for the power up to be completed 2 Call for service Marker not ready OPERATING THE PLATESETTER CAUSE The marker 15 not ready to image SOLUTION Turn the Platesetter off wait 30 seconds turn the Platesetter back on and wait for the power up to be completed 2 Call for service 4 6 SUPPLIES 5 1 SUPPLIES CHAPTER 5 SUPPLIES Introduction Using recommended supplies ensures high quality printing plates and printed output The Plateset ter is designed to image silver halide coated plate material Silver halide material is normally imaged negative right reading see chapter 2 in the section Setup Menu Plate media may be either paper or polyester based Roll width may be from 7 to 13 4 17 8 cm to 34 cm The maximum roll length is 280 85 M SUPPLIES RECOMMENDED CONSUMABLES FOR PLATESTREAM SC PRINTWARE SILVERSTREAM RED LIGHT PLATE MEDIA Emulsion In 5 mil polyester 808555 XXX 280 FT ROLLS 8 mil polyester 808666 280 FT ROLLS Note XXX specifies the specific roll width from 7 to 13 4 CHEMISTRY ACTIVATOR 808777 001 STABILIZER 808777 002 SUPPLIES Tips on Supplies To get the best performance from your Platesetter follow these guidelines for storing and handling supplies Plate Media Handle imaging media by the ends eAvoid ex
14. 4 2 If the solenoid is OK but not being actuated replace the interface PCA 4 3 If the solenoid 1s actuating but the shutter isn t fully opening check that the moveable arm moves freely 4 4 If the moveable arm doesn t move freely loosen the screws that control the arm until it moves freely 50 SERVICE MANUAL GENERAL IMAGER PROBLEMS cont Light leaks 1 Check the light seals around the panels and top cover with a flashlight Also check light panels baffles in and around the processor 3 Move the platesetter away from bright light sources such as windows If this 15 not possible orient the platesetter with the processor end is away from light sources 4 funable to resolve the problem send sample plates to Printware Send 22 long plate with a gray test pattern 51 SERVICE MANUAL GENERAL IMAGER PROBLEMS cont No media or Media not loaded far enough messages Verify that there is media in the machine Manually feed the media up to the capstan roller Check for faulty No Media switch 3 Remove media 3 2 View Sensor Status on Operator Panel 1 means media present 3 3 Manually actuate the No Media switch If 1t the status does not toggle check that the cable is plugged in sufficiently on both ends and check for damage to the cable itself Replace either the cable or the switch If the No Media switch and cable test good but there are still spurious No media or
15. CONTENTS Chapter 1 General Information 16 MERC 1 1 Features Overview 1 4 Operator lt 1 6 Chapter 2 Control Panel The Control a a ar 2 2 Control Panel Menus and FunctlionsS 2 4 Chapter 3 Preparing for Operation Preparing to Make Plates 3 2 Filling the Processor Tanks 3 3 Loading Plate Mod escorts 3 5 2 Suunto EO T 3 8 MimiPlate ODOM uuu 3 9 Chapter 4 Operating the Platesetter Controlling Image Quality ooocccoccncocccnccnnoconcnonanncnannnnnnnnnnnos 4 2 Adjusting Exposure 4 2 Responding to Control Panel Error Messages 4 3 Chapter 5 Supplies iii O eo A unu nu 5 2 Recommended Consumables 5 3 Tips E Poo IO RTT TT TM 5 4 CONTENTS CONTENTS Chapter 6 Preventive Maintenance Introduction rra nere me rrr rhe rennes nnn 6 2 Maintenance 6 3 Chapter 7 Troubleshooting Print Quality Troubleshooting 7 2 General Iroublesho0o0tling
16. December 1 2000 The camera ready master for this manual was generated on a Printware Laser Imaging System and an IBM compatible PC CAUTION The electronic circuitry inside the Platesetter is very sensitive to damage from electrostatic discharge ESD Always follow the ESD protective procedures described in this manual when working on the Platesetter FEDERAL COMMUNICATIONS COMMISSION FCC NOTICE Printware Platesetters generate and use radio frequency If not installed properly a Platesetter may cause interference to radio and television reception Printware Incorporated complies with the limits for a Class A computing device in accordance with the specifications in Subpart J of Part 15 of FCC rules These rules are designed to provide reasonable protection against radio and television interference in a commercial installation The user can determine if this equipment is causing interference to radio or television reception by turning the Platesetter off and on Listed below are measures the user can take to correct the interference a Reorient the receiving antenna b Relocate the Platesetter with respect to the receiver c Move the Platesetter away from the receiver d Plug the Platesetter into a different outlet so the Platesetter and receiver are on different circuits If these measures do not correct the interference problem the user should consult the dealer or an authorized technician for additional suggestions
17. 2 WRAP ITEM 31 AROUND BOTH BEARINGS 2 PLCS b se WRAP ITEM 31 AROUND BOTH BEARINGS 2 PLCS Printware ASS Y STABILIZER TRANSPORT 808049 001 REVISION A Printware Confidential Sheet 2 of 3 DP SIDE SEE NOTE 1 Printware ASS Y STABILIZER TRANSPORT 808049 001 REVISION A Printware Confidential Sheet 3 of 3 Find Number 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 020 021 022 023 024 025 026 027 029 031 032 033 034 035 036 037 038 039 040 041 042 Quantity Component Used 1 12 6 WW N NY NY Ne OA me WN G G GO DW a O Re Assembly Number 808048 001 ASSY ACTIVATOR PLATESTREAM SC Number 807329 001 900960 004 900960 003 806752 001 900960 001 900229 017 806776 001 900960 020 900229 018 807330 001 806694 001 806764 001 900960 002 900582 007 806821 001 806836 001 806760 001 806762 001 90029 1 010 900967 001 901072 004 901071 013 900967 003 901072 005 901089 001 806278 001 8065 10 001 806506 001 806822 001 9003 19 004 901070 001 8068 19 001 806695 001 900773 001 900968 005 9002 15 007 807225 004 Revision A Component Description PLATE ACTIVATOR FRONT BEARING ROLLER GEAR ASS Y GEAR SHAFT IDLER GEAR SPUR E RING SAE 25 SHAFT STUD GEAR GEAR SPUR E RING SAE 312 SHAFT PLATE ACTIV
18. 32 Power Supply Assembly 35 S 36 Chapter 5 Troubleshooting lo a 39 Exposure MOC Sentada e RS 40 Image QualityProblems Artifacts 42 Registration and Skewing 44 SERVICE MANUAL SERVICE MANUAL Operator Panel Problems 46 Marker Galvanometer 47 General Imager Problems 49 Media Jams Imager 54 Imager Module Sensor Problems 55 Cutter Problems 56 Punch Problems uu derit oec 57 59 Processing Quality Problems Artifacts 61 Processor Mechanical Problems 63 Processor Sensor Problems 64 Processor Electrical 65 Media u u ea 68 Press Related Problems Wiring Diagram 70 SERVICE MANUAL CH
19. 600354 001 803418 001 804627 002 803463 001 803466 001 806327 001 808234 002 806473 001 901281 001 900160 011 900287 000 900660 003 806309 001 807091 001 807352 003 807351 001 900230 002 900005 002 807586 001 807585 001 807597 001 806228 001 807063 001 807215 001 807216 001 806352 002 806354 002 807064 001 807354 001 803713 001 807356 001 ASSY ROLLER TRANSPORT SMALL COMMERCIAL Revision C Component Description WELDMENT 13 ROLLER TRANSPORT W ASHER PRELOAD SPRING BEARING BALL RETAINER BEARING ROLLER PINCH TRACTION 13 ROLLER ALUMINUM CAPSTAN E RING SAE 3 8 SHAFT WASHER WAVE SPRING 22MM OD X 01 NUT HEX JAM 5 8 18 BUTTON LOCATING ADJUSTMENT SCREW SHC LOW HEAD 1 4 28 X 1 5 SWITCH TOGGLE SPDT MOMENTARY ASSY LOWER PINCH TENSION ASSY CAPSTAN DRIVE 13 ASSY UPPER PINCH TENSION RIGHT HAND ASSY UPPER PINCH TENSION LEFT HAND PLATE MARKER LOCATING LOWER KEY 1 8 X 1 8 X 3 4 GUARD CAPSTAN PULLEY CLAMP HOLD DOWN WASHER FLAT STEEL 6 NARROW SCREW PHILLIPS PAN HEAD 6 32 X 5 STANDOFF HEX MALE FEMALE 716 32 X 3 4 BRACKET CUTTER MOUNTING ASSY SWITCH SHAFT 15 19 ROLLER FOAM BEARING NYLON SNAP IN 25 SHAFT RING GRIP BRACKET LOWER SOLID MOUNTING GUIDE LOWER SOLID PLATE GUIDE UPPER FRONT BRACKET LOWER SOLID MOUNTING BRACKET BUFFER GUIDE BLOCK EDGE GUIDE ADJ BLOCK EDGE GUIDE POSITIONING PLATE ADJUST PLATE POSITIONING BLOCK BACKUP BRIDGE MEDIA INPUT PULLEY MODIFIED
20. 65 COLLAR PULLEY ASSY PULLEY OVERRUNNING CLUTCH Parts List Page 1 of 3 093 094 125 134 135 136 137 142 151 157 158 167 178 186 192 197 198 201 206 209 236 231 238 250 255 262 263 264 265 266 212 273 274 219 276 277 280 281 282 283 287 290 294 295 N OO PA ha me e e A e Q me A Rh N N e NO 26 here N o N ON 00 oo N OOo GOO Nh Assembly Number 808044 001 807363 001 807359 001 806393 001 900406 006 806267 001 806585 001 900254 002 900039 001 804574 001 806127 001 807050 001 900235 005 900235 035 900229 003 807068 001 807069 001 900235 007 900319 001 900223 000 900160 009 807116 002 807116 003 807456 001 900233 900229 008 900287 019 900233 002 900445 006 900047 000 900445 007 900047 002 90027 1 022 900566 003 900172 002 900160 005 900233 003 900277 004 900963 002 900236 005 900224 005 900235 002 900224 001 900928 003 900235 040 ASSY TRANSPORT SMALL COMMERCIAL Revision C ASSY BELT TENSIONER SHAFT BELT TENSIONER BRACKET BEARING SUPPORT BEARING OIL LESS BRONZE SHAFT MARKER 5 BEARING MODIFIED SELF ALIGNMENT SPACER SHAFT INNER 1 2ID X 1 16 SPACER 171 ID 25 OD 25 HEIGHT PULLEY DUAL CAPSTAN ASSY CUTTER 13 ASSY CAPSTAN GUIDE 13 SCREW SHC 8 32 X 38 SCREW SHC 1 A 20 X 1 2 E RING SAE 1 2 SHAFT BRACKET CUTTER MOUNTING PLATE CUTTER MOUNTING SCREW SHC 4 40 X 5 B
21. General Troubleshooting PROBLEM The Platesetter will not Turn ON No Power Platesetter will not Start a Print Job Reload Media or Manually Reload Media message Platesetter will not Start a Print Job SOLUTION l 2 m l Ensure that the Platesetter is plugged in Check the fuse or breaker for the outlet Try unplugging the Platesetter and plugging another electrical item into the outlet to be sure that it has power The Platesetter may not have completed its power up sequence When the Platesetter is ready the Main Menu will be dis played on the control panel with On Line indicated and no error messages If an error is reported on the control panel correct the problem following the procedure in Chapter 4 then press ESC and P Ensure that the interface cable between the RIP and the Pla tesetter is securely connected at both ends Cycle the Platesetter power Reboot the RIP Media must be reloaded after jams or other fault conditions to prevent a reoccurrence of the jam 2 Reload Media message should clear after reloading 3 If message does not clear check for defective sensor PROBLEM No Plate Exits from Platesetter Plates Jam Skewed Wrinkled or Torn Plates IN CASE OF TROUBLE SOLUTION 1 Ensure that the Platesetter 1s not out of plate media 2 Ensure that the plate media is properly loaded and aligned 3 Open the covers and
22. R42 R43 gt 0 Processor PCA A PCA Screws Blower Figure S2 4 Right Side View of the PlateStream Platesetter 18 SERVICE MANUAL This page intentionally left blank 19 SERVICE MANUAL CHAPTER 3 COMPONENT REPAIR AND REPLACEMENT Replacing Rollers Belts Motors and Cutter Overview This section provides the procedures for removing and reinstalling the following 20 rollers see Figure 52 2 Feed rollers Two pinch rollers left and right One capstan roller Twelve processor rollers NOTES 1 When removing rollers label all spacers in terms of front or rear if any and which roller they were used with For the Platesetter to function correctly all spacers must be placed back in their original positions 2 When replacing rollers note that the new roller shaft may not be precisely the same length as the old roller shaft Install the spacer s on the rear of the shaft with the required thickness to eliminate any front to rear play Spacers are available in four thicknesses 0 016 0 4 mm nominal Part 900254 006 Spacer Inner Shaft 3 8 ID x 016 Th 0 048 1 2 mm nominal Part 900359 Spacer 375 ID x 047 Th 0 063 1 6 mm nominal Part 900254 003 Spacer Inner Shaft 0630 065 Th 0 092 2 3 mm nominal Part 900359 001 Spacer 375 ID x 093 Th 20 SERVICE MANUAL Replacing the Feed Rollers See Figure S2 2
23. WASHER FLAT STEEL 6 WASHER FLAT STEEL 8 WASHER FENDER 5 X 189 X 125 WASHER FENDER 749 X 203 X 156 WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 X 375 SCREW B H TORX 8 32 X 5 SCREW SOCKET HEAD SHOULDER 78 32 X 2505 SCREW SHC 8 32 X 5 8 NUT LOCK 8 32 NUT LOCK K 710 32 SCREW PHILLIPS PANHEAD 10 32 X 1 5 SCREW B H TORX 6 32 X 375 Parts List Page 1 of 2 053 054 056 057 059 077 N N WD L Assembly Number 807501 002 ASSY PUNCH COMBO SC 900047 002 900005 002 900445 001 900608 001 900287 025 806127 004 Revision L WASHER EXTERNAL LOCK 6 RING GRIP SCREW B H TORX 1 4 20 X 5 WASHER FLAT SAE 1 4 SCREW PAN PILLIPS PANHEAD 76 32 X 1 25 ASSY CUTTER 13 R EF ROLL ER ASS EMB Printware Confidential P IN PLACE IN E IN CHASSIS Printware ASSY COMBO PUNCH SC 807501 002 REVISION K Sheet of 1 Pnntware Inc SALES ORDER FORM DATE SALES ORDER NO HOW RECEIVED FAX PHONE E MAIL BY CUSTOMER P O NO CUSTOMER I D NO SOLD TO SHIP TO REQUESTED SHIP DATE SHIP VIA TERMS TAX EXEMPT Y or PHONE NO STATE CREDIT CARD VISA EXEMPTION NO CARD NO EXP DATE ADD L COMMENTS For part cost and availability please call the Sales Administrator at 651 456 1446 For questions r
24. i ANGLES pa TOM PULDSUE WHITE 19 220 ORANGE NU 1 PLACE DECIMALS un FINISH PUMP PRIME BLACK 20 34 YELLOW NU TACE DECIMAIS 5V_PULL UP BROWN 21 35 GREEN NU 3 PLACE DECIMALS 010 SPARE RED 22 36 BLUE NU Cc le NU ORANGE 23 37 VIOLET GUIDE B 45V un GUIDE B 1 S O NU YELLOW 24 38 GRAY GUIDE B SIG SENSOR NO 5 WIRING DIAGRAM PlateStream N O NU GREEN 25 39 WHITE GUIDE B GND NGC COE NU J13 AER NU 807091 001 Z COMM CODE Size INSP VERSION REV 2 FIRST USED ON B 70063 6 00 1 ta A 222 AAN This document and the information it contains is the property of Printware Inc and may not be S EI p lt p gt JP5 EPO Z lt s pw paq p23 SCHEM ATIC P AGE 4 reproduced copied disclosed to others or disposed of directly or indrectly without authoriza SCALE NONE ES sl Dl el Doll E al al Dani Dani Dani Bani Dani C C lov tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 4 f 6 proprietary and may not be used in any manner not consistent with the rights of Printware Inc ee 0 1 2 3 4 5 6 1 2 3 4 5 6 WHEEL CUTTER 110 O o J NU O S
25. 200702 00 49 WHITE GND WHITE 4 J8 ieee 50 BLACK GND BLACK 50 4 RED 4 806793 001 CABLE 804140 002 1 3 NU L WHITE 2 WORKING TANK WHITE NU CABLE 807301 001 ORANGE 4 1 BROWN NO MEDIA 5V V NO MEDIA 806127 001 E 2 RED NO MEDIA SIG SENSOR NO s SENSORS 806800 001 NU 4 807226 001 3 ORANGE NO MEDIA GND e001 60 806099 001 4 YELLOW NU WHITE 5 GREEN NU i SHUTTER 806789 001 were 24V ORANGE 1 6 BLUE NU gt WHITE 1 SHUTTER DRV WHITE 2 7 VIOLET NU a WHITE 324v ORANGE 3 S GRAY NU EXIT SWITCH SHUTTER No 600333 001 NU 4 CABLE or TU ND gt 807204 001 IL BROWN _ NU J6 NU 2 12 RED NU 806788 001 1 BROWN WORKING TANKS LOW V BROWN 1 13 ORANGE NU 8 WHITE l 14 YELLOW NU gt DRIER TEMP SENSOR BLACK 2 3 ORANGE REPLN TANKS LOW ORANGE 3 15 GEBEN NU CABLE 803321 001 T 3 16 BLUE NU 600330 001 NU 1 17 VIOLET NU 2 18 GRAY NU SUPPLY 19 WHITE N DRAWER 20 BLACK NU I 21 BROWN NU 2 10 BLACK GND BLACK 10 mE ND A 06860 INITAL RELEASE DAS 11 22 00 3 11 BROWN SPARE BROWN i 23 ORANGE NU ECO DESCRIPTION DRAWN BY DATE APPVL DATE 2 24 YELLOW NU DRAWN 13 ORANGE 45V PULL UP ORANGE 13 25 GREEN m BY DAS 06 21 00 se E E ENG PRINTWARE INC 27 VIOLET NU O ENG ACT TEMP PROBE RED 1 16 BLUE DRIVE INH BLUE 16 NU gt APPVL 806786 001 BLACK 2 17 VIOLET 45V PULL UP VIOLET 17 207 WHITE NU MFG ST P AUL MN 7 NU 3 30 BLACK NU NU 4 31 BROWN NU QA MATERIAL 20 BLACK P
26. 25 YELLOW CONT 12V 4 13 ORANGE PIX CLK 7 BLUE CONT 12V J4 BLACK GND 10 522980 002 RED 14 YELLOW PIX CLK 26 E CONTIGUA CONTROLLER 15 GREEN PRN DO 8 BLACK CONT GND N 3 16 BLUE PRN D0 SCHEMATIC PAGE 3 17 VIOLET PRN DI 9 ORANGE VENT FAN 24 INTERLOCK PWR 1 18 GRAY PRN DI 28 DC POWER SUPPLY BLACK VENT FAN RTN INTERLOCK ASSY 19 WHITE PRN D2 0 ALL FUSES NC 3 20 BLACK PRN D2 29 TO RIP 901142 001 250 7 CABLE 803312 003 806307 002 21 BROWN PRN D3 1 600322 001 CONNECTORS NOT USED 22 RED PRN D3 30 RED y 45V J2 J5 J15 116 AND SPARE 23 ORANGE PRN D4 2 SWITCH YELLOW INTRF 12V 5V FUSE RED LASER 1 24 YELLOW PRN D4 31 AC IN EMI FILTER BLUE INTRF 12V BLACK GND 2 25 _ GREEN PRN_D5 3 240 VAC CORCOM ORANGE INTRF 424V INTERFACE 803280 001 IR 50 60 HZ 30VK6 BLACK INTRF GND OP PANEL 807220 TAB RED 27 VIOLET PRN D6 4 806420 25 40F RED OP 5V 28 GRAY PRN D6 33 250V 16 522780 TELON OP 12V BLACK GND 6 29 WHITE PRN D7 5 CIRCUIT BREAKER 30 BLACK PRN D7 34 BLUE OP 12V 31 BROWN PRN R W 6 900813 001 BLACK OP GND 52 RED R W 35 GREEN G DRV0 1 GALVO ASSY 34 YELLOW PRN STRB 36 35 GREEN PRN ACK 8 RED G DRVO 4 BLACK G SENSE gt 37 VIOLET PRN GND 9 RED G DRVI 6 38 NC 807049 001 39 NC 40 NC RED SOS C 1 SENSOR ASSY GREEN SOS SIG 2 RED SOT C 4 GRAY SOT REF 6 807151 001 PROCESSOR
27. 806657 002 806706 004 8064 10 002 806410 001 807487 001 901072 004 Revision SCREW STAINLESS TAP FORM 10 32 X 5 SCREW STAINLESS 10 24 X 375 PHILLIPS PANHEAD WASHER SPRING LOCK STAINLESS NUT STAINLESS 10 24 KEPS LOCKNUT SCREW STAINLESS 1 4 20 TPI X 5 WASHER SPRING LOCK STAINLESS GROMMET SCREW SCREW STAINLESS 4 40 X 625 SCREW STAINLESS 8 32 X 375 PHILLIPS PANHEAD WASHER FLAT STNLS 8 3 8 X 11 64 X 031 SCREW STAINLESS 8 32 X 5 PHILLIPS PANHEAD GROMMET EDGE SLOTTED NUT STAINLESS 8 32 KEPS LOCKNUT SCREW STAINLESS 10 32 X 5 PILLIPS PANHEAD WASHER EXT STAINLESS 8 STANDOFF TURN WASHER FLAT STAINLESS BRACKET RACK LOCATING ASSY AIR HOOD ASSY TRANSPORT DRYER ROLLER FOAM 11 ASSY CROSSOVER GUIDE ASSY RACK COVER ASSY TUBE OVERFLOW BRACKET PROCESSOR HEATER HEIGHT BRACKET PROCESSOR HEATER HEIGHT BRACKET COVER ADJUST WASHER SPRING LOCK STNLES 8 055 X 04 Printware Le ASSY PROCESSOR PLATESTREAM SC 808047 001 REVISION B Sheet 1 of 5 Printware Confidential 27 APPLY ALUNG NTIR NGTH OF SE Printware Confidential Printware ASSY PROCESSOR PLATESTREAM SC 808047 001
28. BLACK EE BLACK O d Ul Hi HI 2 O 129 no 12 17 106144214 O E TP4 ACT DRYER PIN 1 IS BROWN PIN 26 IS GREEN n Q E TEMP ACT BLANKET HEATER CAL CAL 600335 001 F1 30 TRANSFORMER WIRING DIAGRAM O PS46 808155 001 523 150 001 PSMP 807346 001 PS 807179 001 523200 001 EMI FILTER e E 2A 250V E HEATER FAN 806705 001 5A 250V F3 5A 250V E J4 J5 2A 250V DRYER HEATER BLACK DRAWN 806712 001 BROWN BY DAS 11 22 00 BLACK ENG PRINTWARE INC ENG O APPVL Z MFG ST PAUL MN BROWN 2 Q A MATERIAL BLUE 2 TOLERANCE UNLESS OTHERWISE SPECIFIEI S L ANGLES sd 5 DEG BROWN GND GREEN POWER SUPPLY I 1 PLACE DECIMALS zin FINISH 220V gt 2 PLACE DECIMALS 02 YELLOW GREEN B BLUE O 3 PLACE DECIMAL S 010 UN 806843 001 Zi COMM CODE Size 700636 001 INSP VERSION REV 2 FIRST USED ON B A This d d the infi ion i ins is th f Pri Inc and b SCHEMATIC PAGE 6 copied dolosa ole NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 6 f 6 proprietary and may not be used in any manner not consistent with the rights of Printware Inc ee o
29. Backup Length can be used to adjust or eliminate the gap between Miniplate jobs 1 To turn Miniplate Mode ON from the Main Menu on the control panel Press 1 Setup Press 6 Destination e Select Processor Miniplate as the output destination 2 To enable Miniplate Backup from the Main Menu on the control panel Press 4 More Information e Press 6 Miniplate Backup Press ON to turn Miniplate Backup ON enabling calibration of the gap between Miniplate jobs e Press 5 to select Miniplate Cut Length Set to the intended plate length e g 12 then press ENTER to save 3 To run a test plate from control panel Main Menu Press 2 Test Plate Press 3 Choose Length Set to the approximate intended length of the Miniplate jobs e 2 4 then press ENTER to save e Press 2 Choose Pattern Use the ON 4 key or the key to scroll through the patterns Select the Screen pattern then press ENTER to save e Press 1 Run XX Plates Enter the number of jobs per miniplate Press ENTER to image a Miniplate test plate Press ESC to return to the Main Menu 4 To calibrate the gap between Miniplate jobs from the More Information Menu e Press 2 to go to the Calibrate Menu e Press 1 Calibrate Transport e Press 7 Miniplate Backup Length Adj 5 To decrease the gap between jobs inc
30. Connect the ribbon cable from the harness assembly to J9 on the PCA 14 Open accessory boxes and remove bubble pack from contents The contents should include a The RIP and PlateStream manuals on CD s b Two optional plastic replenishment tanks and optional small replenishment cart c Effluent tank d A wire tray e Two media spools and one media shaft f Tube with plate samples 15 Insert wire tray into slots located on the top right side of the Platesetter 16 Attach customer supplied power plug to Platesetter power cord located in the rear of the machine per electrical wiring codes Assembling the Processor 1 Remove black tape holding the activator and stabilizer racks Remove the four styrofoam pieces located in the front and rear of the processor working tanks inside the Platesetter Remove bubble pack wrapped around Cover E Guide F and overflow tubes 2 Place the overflow tubes in the large holes located in the rear of the processor working tanks inside the Platesetter Press down until overflow tubes stop Place the spring pin from Guide F into the hole located in the rear of the activator tank while placing the other pin into the hole located in the rear of the stabilizer tank Slide Guide F towards the rear of the Platesetter while placing pins on the other side of Guide F into the holes located in the front of the activator and stabilizer racks INSTALLATION GUIDE 3 Place the two optional replenishment tanks
31. GUIDE LABEL PLATE GUIDE POSITION EDGE GUIDE SPRING TRACTION CONTROL 13 ASSY SOLENOID CAPSTAN GUIDE ASSY SOLENOID CAPSTAN GUIDE SCREW SOCKET HEAD SHOULDER 28 32 X 125 Printware ASSY ROLLER TRANSPORT SC 808044 001 REVISION Sheet 1 of 3 lt VY V ID Y e ASSEMBLY A ASSEMBLY G ASSEMBLY J c3 e UC xo T eo c3 Am ASSEMBLY H ASSEMBLY B ASSEMBLY C USE AS REH D FUR PRUPER SPACING ASSEMBLY C2 ASSEMBLY C ASSEMBLY A a i ASSEMBLY Printware ASSY ROLLER TRANSPORT SC 808044 001 REVISI N F Sheet 2 of 3 Printware Confidential E e g LA oK _ 472 E 1 Gu d 2 L 90 ASSEMBLY J SEE SHEET ASSEMBLY IP ASSEMBLY GC Printware ASS Y ROLLER TRANSPORT SC 808044 001 REVISION F Printware Confidential Sheet 3 of 3 Find Number 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 018 019 020 021 022 023 024 025 026 027 029 030 031 032 033 Quantity Component Used UJ A A WO N N OO m N KF HH n NO 5829 0 O
32. Input Spools see 5 below eliminating the need to reset image width every time the spool is changed 5 Input Spool Selects the input spool The choices are A B C or D The media remaining for the selected spool decreases as media is imaged see Spool Manager later in this chapter Each spool can hold up to 280 85 m each spool s counter can be reset after reloading Input spool selection will be displayed in front of the feet remaining in the main menu 6 Destination Sets the output destination for the imaged media Choices are Processor or Processor Miniplate with the Miniplate option For a standard PlateStream SC with no options installed Processor is the only destination 7 Display Units Toggles between English and Metric display units NOTE This manual generally refers to English display units with Metric units in parentheses where applicable CONTROL PANEL Test Plate Menu Test Plate ESC to exit Run 01 Plates 2 Choose Pattern Composite Pattern 3 Choose Length 13 Transporting On Line A0000 2400 DPI PROC ON ESC OFF ENTER 1 Run nn Plates Sets the number of plates from 1 to 99 Pressing ENTER sets the specified number of plates to be printed Pressing ENTER again causes the specified number of plates to be printed As each plate is printed the displayed number will decrement by 1 Printing can be interrupted by pressing the ESC key If printin
33. PANEL PROC Imager destination lower right corner of operator panel PROC Imager is in processor mode MINI Imager is in miniplate mode there are No accumulated miniplates in the imager MINI3 Imager is in miniplate mode there are 3 accumulated miniplates in the imager if there are more than 9 accumulated miniplates the digit changes to a Setup Menu gt ESC to exit Image ore Resolution Image Power Media Width 13 gt Spool Pos 13 Input Spool Destination T Display Units English ON ESC OFF ENTER 1 Image This selection sets the type of imaging for the different types of media The choices are Positive or Negative Wrong Reading and Positive or Negative Right Reading 2 CONTROL PANEL 2 Resolution Sets the resolution of plates imaged from the control panel The PlateStream SC runs at 2400 dpi 3 Image Power Sets the image power laser intensity Increasing image power increases D or Density while decreasing image power reduces D 4 Media Width xx xx Spool Pos yy Media Width is the exact width entered by the operator from 7 00 to 13 40 17 78 cm to 34 00 cm Spool Pos is automatically calculated from Media Width and indicates the position to set the spool or cassette Spool position is set at the media width in inches rounded to the nearest inch from 7 to 13 Media Width is set independently for each of the
34. PULLEY TIMING BELT 1 5 PITCH 006 3 901079 001 PIN SPIRAL Printware ASSY PROCESSOR DRIVE SHAFT 0671 0 001 REVISION E Sheet of1 Printware Confidential Assembly Number 806714 001 ASSY DRYER DRIVE Revision G Find Quantity Component Component Number Used Number Description Parts List Page 1 of 1 001 2 900960 004 BEARING ROLLER 002 1 900271 004 BELT TIMING 1 5 PITCH 100 GROOVES 003 1 900960 002 GEAR WORM SINGLE 004 1 900582 007 PIN DOWEL SST 125 DIAMETER X 625 LARGE 005 1 900268 008 PULLEY TIMING BELT 1 5 PITCH 006 1 606 770 001 SHAFT DRIVE BELT 007 1 900229 017 E RING SAE 25 SHAFT 008 1 606 729 001 CHANNEL DRIVE DRYER Printware ASSY DRYER DRIVE 80671 4 001 REVISI N G Printware Confidential Sheet of 1 Find Number 001 002 003 005 006 007 008 009 010 011 012 013 014 015 016 018 019 020 021 022 023 024 025 026 028 030 031 032 033 034 035 036 037 038 039 040 041 Quantity Component Used 1 12 5 O N N N NO NNNNA WAR C a GO CO N N Ln Y Assembly Number 808049 001 ASSY STABILIZER PLATESTREAM SC Number 807331 001 900960 004 900960 003 806752 001 900960 001 900229 017 806776 001 900960 020 900229 018 807332 001 806764 001 900960 002 900582 007 806821 001 806837 001 806762 001 806760 001 806278 001 806836 001 900967 001 901072 004 901071 013 900967 003 9
35. Punch Alignment Figure I 16a Punch Alignment and Skew Figure I 16b Punch Alignment and Skew 23 INSTALLATION GUIDE Adjusting Punch Length with punch option installed 1 To enable the punch from the Main Menu on the control panel Press 4 More Information e Press 8 Punch e Press ON to turn the punch on 2 Runa test plate with the punch on 3 Return to the Calibrate Transport menu Press 4 More Information Press 2 Calibrate Press 17 CalibrateTransport Punch Notches Larger punch length produces deeper notches Figure I 17 Adjusting Punch Length Bacher pattern 4 Measure the depth or position of the punch notch see Figure I 17 or I 18 For the Bacher punch pattern see Figure I 17 the notch depth should be 0 433 11 0 mm For the pin bar pattern see Figure I 18 the center of the holes should be 5 16 0 313 or 8 0 mm from the edge 226 TO 1235 9 4 0 9 Figure 1 18 Adjusting Punch Length Pin bar pattern 24 INSTALLATION GUIDE 5 To increase the depth increase the value for Punch Length Adj and increase Backup Length Adj by the same amount there is a separate set of Backup Length values with the punch enabled Decreasing the values decreases depth 6 If necessary follow the procedure for all resolutions to be used with the punch mode Punch and Back
36. REVISION B Sheet 2 of 5 Printware Confidential EEP GROOVE THIS SIDE Printware ASSY PROCESSOR PLATESTREAM SC 808047 001 REVISION B Sheet 3 of 5 Printware ASS Y PROCESSOR PLATESTREAM SC 308047 001 REVISI N B Sheet 4 of 5 Printware Confidential Printware Confidential 44 PLACES D Q gt MSS SZ ALIAS S Z Y lt A p i Printware SS Y PROCESSOR PLATESTREAM SC 808047 001 REVISION B Sheet 5 of 5 Assembly Number 806710 001 ASSY PROCESSOR DRIVE SHAFT Revision E Find Quantity Component Component Number Used Number Description Parts List Page 1 of 1 001 1 806775 001 SHAFT DRIVE 002 3 900960 019 GEAR WORM 003 1 901090 001 BEARING THRUST 004 1 806824 001 BEARING FLANGE MODIFIED 005 1 900268 005
37. S3 1 The cutter assembly consists of a frame DC motor and position sensor 1 Open the top cover and raise the marker 2 Disconnect the cutter cable assembly 3 Loosen do not remove the 2 op side allen screws and remove the 2 non op side screws 4 Access the cutter assembly from the top of the Platesetter and remove the cutter by sliding the cutter towards the rear of the platesetter 5 Install the new cutter in reverse order Lower the marker and close the top cover Replacing the Processor Rollers See Figure S2 2 S2 3 There are thirteen rollers six in the activator rack and seven in the stabilizer rack 1 Open the top cover 2 Remove Cover E Remove Guide F by pressing guide towards the rear of the Platesetter lift guide from the front of the Platesetter and remove Remove Guide D by pressing the guide towards the front of the Platesetter lift the guide from the back of the Platesetter and remove 3 Remove the rack from the Platesetter 4 Remove the gear from roller by loosening one set screw Remove the spring if any and the bearing if any 5 Remove the roller by sliding the roller towards the front of the rack until it clears the frame 6 Install the new roller in reverse order Close the top cover 24 SERVICE MANUAL Replacing the Marker Unit CAUTION The Marker Housing contains potentially harmful invisible laser energy Do not attempt to open the inner covers other than described in this m
38. SOS SOT sensors J14 Galvanometer control J15 Not Used Spare Not Used 28 SERVICE MANUAL Replacing the Controller PCA The non volatile SRAM on the controller PCA stores the total plate count image quality settings image position settings and marker assembly calibration values All of this information will be lost when the controller PCA is replaced If possible look through all the menus on the control panel before replacing the controller PCA and write down all the settings Image quality and position settings can be re entered from the control panel after the PCA is replaced The plate count and material used count will start over from zero so keep a record of the values read from the old controller PCA with the Platesetter The marker assembly calibration values will be regenerated during the marker assembly calibration procedure If the image settings and plate count values cannot be read due to a massive controller PCA failure use the information from the customer s operator log for resetting these values Before beginning the replacement procedure record the following information punch values are applicable only if this option is installed Resolution 2400 Cut Length Overlap Length Backup Length Punch off Backup Length Punch on Punch Length Punch on Miniplate Backup Length Image Power Processor amp Mini Plate MT Speed __ 1 Turn off the Platesetter and open the top cover 2 Replace the con
39. Spool Assembly Figure 3 2 Location of Spool Assembly EMULSION IN MEDIA Right Hub Figure 3 3 Loading Plate Media on Spool 3 PREPARING FOR OPERATION Imaging Plates 1 Configure RIP Connect to the Network ZAPripHQ Harlequin Xitron RIP pa Press ctrl alt del to log on Log in as Administrator with password printware Double click on the ZAPrip icon Choose Start Inputs from the Xitron RIP menu to start the RIP 2 Print a Job a b Be sure your front end computer see the network hot folder The ZAPrip HQ Harlequin RIP can use the Mac chooser as well as a hot folder To set this up use the chooser to select the desired PlateStream output device and resolution If a print driver is required use Adobe 4 2 for WIN95 98 Adobe 5 for NT Create a test job whose document size is equal to the desired plate size Print the job saving it as a PostScript file in the spool hot folder or using the print command if using set up with Mac chooser PREPARING FOR OPERATION MiniPlate Option With the MiniPlate option the Platesetter accommodates jobs shorter than the 12 minimum plate length by imposing several small jobs down the length of a plate To turn MiniPlate on change the destination to Processor MiniPlate in the Setup Menu see chapter 2 in the section Setup Menu The minimum job length is 1 MiniPlate accumulates shorter jobs until the combined le
40. UY N N CO Assembly Number 804627 002 ASSY CAPSTAN DRIVE 13 Number 804370 001 804357 001 804356 001 804358 001 804355 001 804354 001 806308 001 803391 001 804359 001 900800 001 900781 008 804628 001 900767 001 900296 900229 001 900340 900235 013 900047 002 900287 020 900160 005 900336 001 900047 003 900652 014 900288 000 900445 900223 005 900226 004 900340 003 900160 006 900235 000 901095 005 Revision N Component Description PLATE DRIVE MOUNTING PLATE PULLEY MOUNTING BASE PLATE PULLEY MOUNTING LEFT SIDE PLATE PULLEY MOUNTING RIGHT SIDE PLATE MOTOR BRACKET MOUNTING BRACKET MOTOR MOUNTING CAPSTAN BRACKET CAPSTAN DRIVE MOUNTING PLATE CAPSTAN DRIVE BEARING ADJUST PULLEY COATED CAPSTAN LOWER BELT FLAT BELT FLAT 11 5 X 4 X 018 ASSY MOTOR STEPPING GROMMETS VIBRATION ISOLATOR BEARING BALL FLANGED E RING SAE 1 4 SHAFT SCREW SOCKET HEAD CAP 10 32 X 1 2 SCREW SHC 6 32 X 25 WASHER EXTERNAL LOCK 76 SCREW PHILLIPS PANHEAD 738 32 X 1 WASHER FLAT STEEL 8 NUT SELF LOCKING HEX 118 32 WASHER EXTERNAL LOCK 10 SPACER ROUND 8 X 1 4 SCREW PHILLIPS PANHEAD 10 32 X 1 2 SCREW B H TORX 10 32 X 625 WASHER LOCK HELICAL SPRING 710 SPACER SHAFT 553 5 SCREW SOCKET HEAD CAP UNIT 10 32 X 3 4 WASHER FLAT STEEL 10 SCREW SHC 138 32 X 75 SCREW SET OVAL POINT 10 32 X 5 16 Parts List Page 1 of 1 Printware Confidential Print
41. a key is pressed that has no effect the control panel will emit a beep The PC keyboard may also be used directly to operate the Control Panel To minimize the Control Panel click on the lower right corner of the Control Panel This will leave the display but hide the keypad DO NOT close the Control Panel program upper right corner box while the imager is operating this will cause the interface to crash and the imager to malfunction 2 2 CONTROL PANEL Printware PlateStream SC 1 Setup 5 Load 2 Test Plate 6 Cut Fd 3 On Off Line 4 More Information On Line Idle 0000 2400 DPI PROC E di Test Plate More Information b 21 2 v 1 Run 01 Plates 1 Run Hardware 8 Punch OFF 3 Image ener 05 2 Choose Pattern Composite Pattern 2 Calibrate 4 Media Width 13 12 Spool Pos 13 110 3 Status H Input Spool k l On Line Idle A0000 2400 DPI 4 Backup Feed Transport 6 Destination Processor 5 Miniplate Cut Length 12 7 Display Units English EROR 2 P E Guide B Sensor h Calibrate Run Hardware Status 1 Calibrate Transport 1 Transport Motor OFF 5 Reset Proc 2 Calibrate Marker 1 Sensor Status 2 Cut Plate 6 StartProc 3 Input Spool Manager 3 Shutter Close 7 Prime Pump 4 Marker Position 00 00 2 Current Plate Count 000125 4 Punch Plate 5 Save Imager Setup to RIP Total Plate Co
42. a plate which calibrates the processor exit sensor for 2400 dpi The processor exit sensor is calibrated at the factory If the control panel error displays Media didn t exit imager or Media didn t exit processor calibrating the processor 15 one of the possible solutions Ensure that destination is set to Processor then Calibrate the processor by pressing ENTER The Plateseetter must be in Processor mode to calibrate the processor For more details on menu items 2 7 see Physical Calibration in the INSTALLATION GUIDE 2 Manual Length Adj Incremental corrections to obtain the correct plate length The length change displayed is reset to 0 after pressing enter At 2400 dpi the manual length is adjustable in 0 002 0 005 cm increments The length will not be changed if the increment entered is less than the minimum increment size 3 Cut Length Adj Sets the length of the trailing edge of the plate 4 Overlap Length Adj Sets the length of plate that is double exposed on the leading edge 5 Backup Length Adj Adyusts the length of the leader there 15 a second set of values with the punch option installed 6 Punch Length Adj Only with the punch option installed Adjusts the punch position on the plate 7 Miniplate Backup Length Adj Only with the Miniplate option installed Calibrates or elimi nates the gap between jobs in Miniplate mode 2 13 CONTROL PANEL Input Spool Manager Men
43. and then back on 5 Close the top cover Interface PCA Location and Function The interface PCA is located next to the power supply in the back of the machine See Figure S4 1 The interface PCA is the interface between the controller PCA and the Platesetter engine assemblies The interface PCA also receives the signals from the various sensors within the Platesetter The interface PCA also sends control signals to the engine stepper PCA to activate the stepper motors 30 SERVICE MANUAL Voltages Supplied to Interface PCA 12 VDC 12 VDC 5 VDC 24 VDC Connector Assignments Not used J2 Marker cooling fan J3 Punch control option J4 Not used J5 Shutter solenoid J6 Not used J11 Engine stepper PCA J12 Controller PCA control panel communication cable J13 Not used J14 Processor communication cable J15 Sensors J16 Power Supply 3l SERVICE MANUAL Replacing the Interface PCA 1 Turn off the Platesetter and remove the front panel 2 Replace the interface PCA as follows a Access the interface PCA from the rear of the Platesetter b Disconnect all cables Note the correct orientation of each cable c Carefully remove the interface PCA by unscrewing the 4 standoffs which attach the inter face PCA to the power supply d Install the new interface PCA in reverse order Replace the rear panel Engine Stepper PCA Location The engine stepper PCA is located next to the power supply in the back of
44. are described below Power on off switch ckt breaker 20 amp e Connector J1 engine stepper PCA Connector J2 not used Connector J3 not used Connector J4 controller PCA Connector J5 interface PCA Replacing the Power Supply Module Turn the Platesetter off and unplug Remove the rear panel 2 Disconnect the cables from the power supply Note the orientation of each cable Disconnect the power connections for the processor These connections are located in the processor PCA bay on the terminal strip labeled TS1 connection blocks 1 2 and 3 3 Remove the 6 3 8 nuts which attach the power supply assembly to the platesetter chassis These nuts are located inside the platesetter on the rear panel 4 Remove the power supply assembly from the platesetter chasis 5 Install the new power supply in reverse order Replace the rear panel 35 SERVICE MANUAL Sensors The sensor Status menu indicates the current digital status of all Platesetter sensors Explanation of all the sensor indications are shown below NO MEDIA Identifies the amount of media in the spool as okay or none A 0 indicates that the media supply is empty 1 indicates that the amount is sufficient GUIDE B Indicates the presence of media at Guide B A 1 indicates that media is present e g during imaging A 0 indicates the sensor is clear This is the normal idle condition WRKNG TANK LOW This sensor monitors the
45. can be specified in the front end application or can be overridden and specified in the RIP The three halftone parameters to be specified are 1 The shape of the dots created 2 The frequency and angle of the dot pattern 3 The screening algorithm i e conventional AM or enhanced supercell screening HALFTONING AND SCREENING Dots Halftone Cells and Screens Dots are the visible part of halftoning and most halftoning can be described in terms of patterns of these dots The industry standard terms used to describe the organization of these dots into manage able structures are halftone cells and screens Each dot is considered to occupy a halftone cell Figure ApC 1 shows two groups of four halftone cells Every halftone cell is used to represent a gray level or color intensity A dot can have any area in the range 0 of the area of the halftone cell a completely white cell through 100 of the area of the halftone cell a completely black cell Dots of intermediate areas create the illusion of gray levels The number of pixels in the halftone cell defines how many intermediate areas of dot are possible and in most systems this defines the number of reproducible grays 1 Cell spacing related to line screen Figure ApC 1 Halftone cells Screen Frequency and Dot Shapes A screen is an invisible grid that is superimposed on the image each square in the grid is a halftone cell For a particular dot shape the imp
46. clear silver During imaging the Start Of Scan SOS sensor on the marker unit counts the number of scan lines being imaged on the plate at 2400 scan lines per inch Once the correct number of scan lines have been imaged the marker unit keeps the laser turned on to expose the trailing edge of the plate Once the entire page is imaged the media advances to the cutter The cutter cuts the media to a specified plate length After the media is cut and punched if the optional punch is installed it is fed into the integrated processor 2 Activating Developing a base chemical process which etches the image on the media This is done by the activator on silver halide plate material 3 Stabilizing Fixing a slightly acidic chemical process which stops the developing This is done by the stabilizer on silver halide plate material 4 Drying air drying of the processed media Unless another file is sent immediately the Platesetter returns to idle mode The capstan motors is shut off The processor transport motor and dryer are also shut off Marker Marker d Pinch Roller 4 Cutter 4 Optional Punch Media Input Spool Input guide Exit guides Media Path vU Y 1 3 Figure 1 3 Media Path of the PlateStream Platesetter I O Panel High Speed Media Loading Control Panel Power Switch Options GEN
47. depends on the plate width 3 With a9 64 Allen wrench loosen the two screws on the Operator side and one screw on the Non operator side of the punch assembly see Fig I 15 4 Center the punch pattern on the plate by adjusting the Lateral Adjustment Screw both adjustment screws require a 9 64 Allen wrench Tightening the phillips screw clockwise moves the punch pattern toward the operator side Each turn moves the punch approximately 0 030 0 08 cm Loosen these screws to adjust 1 E Lateral Adjustmen Skew Adjustment Figure I 15 Lateral and Skew Punch Adjustments wa a O w a ra Non operator side 0 o O 22 INSTALLATION GUIDE Punch Skew 1 Refer to Fig I 16a or I 16b for plate measurements e If A B loosen the 2 locking screws on the Operator side and turn the Skew Adjustment Screw counterclockwise Each turn moves the punch approximately 0 030 0 08 cm f A gt B turn the Skew Adjustment Screw clockwise 2 After adjustment run another plate to check for punch skew 3 Continue adjusting punch skew until the punch pattern is sufficiently parallel to the image 4 Tighten the two locking screws on either side of the punch assembly Operator side notch d Pattern Non operator side notch lt Lateral
48. essential to keep the Plate setter in proper operating condition and to maintain optimal image quality Keeping the Platesetter and its surrounding area clean is also important Wipe excess oil from all parts after performing lubrication procedures Perform these procedures at the time intervals shown in the Platesetter Maintenance Schedule section to keep the Platesetter operating properly and avoid unnecessary repairs For detailed drawings and Printware replacement part numbers see the PlateStream Platesetter Parts Manual Approved Lubricants The following lubricants are the only ones approved for use on the PlateStream eMobilith SHC 460 eSilicone Stick Lubricant Cleaning Supplies Marker Mirrors eCompressed air recommend type in Ultrajet E Series Precision Dust Remover e Acetone 100 pure cotton non woven lintless non scratching fabric such as Webril Wipes Imager rollers eNon linting soft cotton cloth eCleaning refreshing solvent Recommended type is D Ink Processor Rollers Non linting soft cotton cloth Warm soapy water SERVICE MANUAL Printware Recommended Periodic Maintenance Schedule Recommendations based on 8 hours per day use 5 days a week 1 Imager section maintenance Weekly Q Roller cleaning damp cloth light D ink no alcohol or solvents Q Clean or replace fan filter LI General cleaning of dust dirt from imager area Q Clean out any punch chips from optional punch area of machin
49. motor speed Check for small pieces of media stuck near the cutter NOTE This problem is often reported after an error message prompts the user to cut a plate If the cut plate is not removed Guide B jams can result Current firmware prompts the user just to back up and not cut after certain errors I 2 Adjust the cutter infeed guides Adjust the cutter blade see procedures under Cutter cycles but doesn t cut 54 SERVICE MANUAL IMAGER MODULE SENSOR PROBLEMS Guide B Sensor blocked 1 Ensure that the cable harness is plugged into the sensor 2 Check for any pieces of media that may be stuck in the punch 3 Remove the rear panel and use a flashlight to see if there are any scraps of media in the punch cutter path Guide B Sensor faulty 1 Ifthere is no media blocking the guide B sensor the switch may be damaged From the Operator Panel go to the Sensor Status menu to test the switch 2 Open top cover Lift capstan guide arm and separate the capstan roller from the pinch roller on the exit side of the imager Push a piece of paper through these rollers and the center of the punch assembly over the sensor The Sensor Status should toggle between 1 and 0 as you activated and deactivate the sensor Current firmware will show a 1 when engaged and a 0 when disengaged Older firmware may show the opposite status numbers but will still toggle between them Move the paper over
50. on the optional smaller cart 4 If necessary prepare the Activator and the Stabilizer solutions in the replenishment tanks following the manufacturers instructions Fill the processor working tanks inside the Platesetter and the replenishment tanks with the solutions Make sure the activator tank 1s filled with activator and the stabilizer tank 1s filled with stabilizer Place Cover E over processor working tanks 5 Remove the bubble pack from the replenishment probes located underneath the processor and insert probes into the replenishment tanks by screwing on the white cap Remove the bubble pack from the optional effluent probe located underneath the processor and insert probe into the hole on top of the effluent tank 6 Rotate the gears in the activator and stabilizer racks several times to free them up before operating the Platesetter Close the top cover Installing the Raster Image Processor RIP Unpack the RIP central processing unit CPU and inspect it for any obvious physical damage If any component appears damaged notify the carrier immediately 2 Unpack the RIP keyboard 3 Unpack the RIP monitor 4 Plug the monitor cable into the back of the RIP CPU this cable should fit only one way 5 Connect the keyboard cable to the keyboard connector on the back of the RIP CPU 6 Attach the network cable to the network interface connector on the back of the RIP CPU 7 Plug in the RIP electrical power cord s 8 Con
51. only Never ground the cord to a gas pipe or a water pipe Keep the cord away from hot surfaces Avoid using an extension cord 5 Usecaution when disconnecting any electrical connector within the Platesetter Do not disconnect electrical components with the Platesetter turned on 6 Beextremely careful when working on the Platesetter with the machine turned on and the top cover open Notice the warning label attached to the underside of the laser marker unit 7 Always read and follow all label instructions on supplies carefully Dispose of used supplies and containers appropriately 8 Use caution when working on or around rollers within the Platesetter with the power on Be especially careful when wearing loose fitting sleeves or a tie Follow similar precautions when working on or around the cutter 1 6 GENERAL INFORMATION 9 Do not operate the Platesetter if any part of it is damaged or if any part has been dropped until you have it checked by an authorized service technician 10 When turning OFF the Power switch be sure to do it after the machine cycling has come to a complete stop 11 Use only supplies designated by Printware with your Platesetter Consult the recommended supplies list that came with your Platesetter system All supplies should be stored in a cool dry area The use of low grade or improperly stored media will result in print quality problems 12 There is a lithium battery in the battery backup RAM on th
52. or FAX message Toll free U S A only 1 800 456 1400 FAX Number 612 454 3684 Be prepared to provide Technical Support with the following information Customer name Platesetter serial number Marker serial number Description of print quality problems you are having Description of Folding Mirror surface cleanliness Steps you have taken Request to remove Marker lower cover to inspect and possibly clean the other mirrors If appropriate Technical Support will authorize you by telephone or FAX message to remove the marker assembly unit lower cover to examine the other mirrors and to clean these mirrors if neces sary Technical Support may also offer suggestions to correct the print quality problem other than mirror cleaning 10 SERVICE MANUAL Inspecting the Galvanometer Window Reversing Mirror Spherical Mirror and the Folding Mirror Get authorization to remove the marker lower cover See the previous procedure Open the top cover and raise the marker Remove the marker lower cover by unscrewing the 4 Allen head screws with flat washers located underneath the marker Refer to Figure S2 1 This will break the warranty void seals Inspect the surfaces of the galvanometer window the reversing mirror the spherical mirror and the folding mirror Refer to Figure S2 1 If no dust particles or other particles are present on the mirror surfaces reinstall the marker assembly unit lower cover If this 1s the case t
53. or two depending on use I Setting Maximum Density Before calibrating dot density maximum density D 15 set by adjusting laser power from the PlateStream operator panel There are several ways to do this A Using an exposure file l From the RIP run file 805346 1 ps using the lowest resolution that your PlateStream 15 set up for 1 e 2400 for the PlateStream SC Use a page setup from the RIP that corresponds to this resolution 2 With the unaided eye look at the 3x3 4x4 and 8x8 checkerboard patterns Note for the PlateStream SC ignore the 1x1 and 2x2 patterns as they will nearly always be too dark 3 If all 3 patterns look the same density the same grey level the image power 15 correct 4 If the patterns get lighter grey going from 8x8 to 3x3 with 3x3 being the lightest the image power is set too low Increase the image power and run the file again Again look at the patterns to determine if the grey level is acceptable This image power 15 made from the op panel main menu as follows 1 Setup enter Verify that the resolution shown after 2 is the same as you ran the file at 3 Image Power type in ahigher or lower image power setting number enter Then re run the file B 2 CALIBRATION 5 If the patterns get darker grey going from 8x to 3x3 with 3x3 being the darkest the laser power is set too high Decrease the laser power and run the file again and again look at the patterns to determine if t
54. panel and remove cover E from processor See figure 3 1 2 If necessary prepare the Activator and Stabilizer solutions in the plastic replenishment containers following the manufacturer s instructions 3 Remove probes from the replenishment containers Fill the processor working tanks inside the Platesetter and the replenishment containers with the proper chemistry Reinstall the probes into the replenishment containers Make sure the activator tanks are filled with activator and the stabilizer tanks are filled with stabilizer Place cover E over processor working tanks Replace front panel 4 Remove the probe and hose from the effluent tank Remove the effluent tank and empty it Be sure to dispose of or recycle the spent chemistry in accordance with local regulations 5 Reinstall the probe and hose into the effluent tank Reinstall the effluent tank Replace the front panel PREPARING FOR OPERATION Marker Lever Y Marker 7 Capstan Roller Pinch Roller Media Input Spool Input guide Exit guides d Dryer Section Processor Working Tanks Media Path OO oO Activator Stabilizer Tank Tank Figure 3 1 Side View of the PlateStream Platesetter Processor Note If the processor has not been in use for several days the racks can freeze up due to evapo ration causing rollers to stick together The racks should be removed and ri
55. required Steps for Calling for Service 1 Observe and write down the control panel error display if applicable 2 Turn off the Platesetter 3 Write down the Platesetter model number and serial number located on the rear cover 4 Be prepared to provide the service technician with a complete description of the problem 5 Only an authorized service technician should be allowed to service the Platesetter If you are unsure of whom to call to arrange for servicing then call Printware s Customer Service Department at 800 456 1400 7 12 SPECIFICATIONS APPENDIX A SPECIFICATIONS Resolution 2400 dots per inch dpi Up to 175 line per inch 70 line per cm screen rulings Imaging Throughput 14 in min 34 cm min at 2400 dpi Processing Throughput 36 in min 46 cm min at 2400 dpi Image Width 13 4 34 cm 81 picas Plate Size 13 4 22 max 7 x 12 min 34 x 56 cm max 17 8 x 30 5 cm min Plate Cutter Automatically cuts to size Waste Reduction Mode Reduces leader to 0 7 1 8 cm Miniplate Option Integrated imposition software allows up to 5 images per plate Exposure Laser 650 nm red laser diode Spot Size 25 micron nominal diameter Repeatability 0 001 25 microns typical 4 consecutive plates Image to Edge Accuracy 0 003 75 microns typical A 2 SPECIFICATIONS User Settings Right wrong reading and reverse Laser intensity 0 100406 Variable Image offsets Recommended M
56. s top cover and adjust the marker focus screw using a 7 32 allen wrench Turn the focus screw 3 full turns clockwise see Figure 52 1 Close the top cover Run another 4 pixel on focus test plate 4 Compare to previous plate If the focus pattern looks better you are turning the focus screw in the right direction Continue turning the focus screw 2 full turns at a time and re imaging another focus pattern and observe the results again 5 If the pattern looks worse turn the focus screw 6 full turns CCW close the cover and run another focus pattern 6 Repeat whatever parts of steps 3 4 amp 5 that are necessary until test plates are in focus Note that there 15 approximately an 8 to 10 turn range on the focus screw where the marker is in focus The best focus will be obtained in the middle of that range 12 SERVICE MANUAL 13 rr tt EEUU Note the sharp clean focused pattern above vertical and horizontal lines approximately the same width and are full and sharp in both the positive and negative modes 4 pixel on focus patterns Note the fuzzy un focused pattern below vertical and horizontal lines are fuzzy and may not be the same width SERVICE MANUAL Processor Section Operation Safeguards 1 Do not spill liquids into the electrical compartment or on other electrical components Do not operate the processor if electrical components have been damaged 2 Disconnect electrica
57. solution level in the working tanks within the processor A 0 indicates the current level is okay a 1 indicates a low solution level in one or both of the tanks REPLN TANK LOW This sensor monitors the solution level in the replenishment tanks under neath the processor A 0 indicates the current level is okay a 1 indicates a low solution level in one or both or the tanks EFL TANK HIGH This sensor monitors the level of spent solution in the optional effluent tank underneath the processor A 0 indicates the current level is okay 1 indicates the tank needs to be emptied PROC TEMP OK The processor Activator temperature sensor monitors the temperature of the Activator bath A 0 indicates that the current temperature is okay a 0 indicates that the bath is still warming up or that there is a problem with the heater PROC EXIT Indicates the presence or absence of media at the processor exit sensor A 1 indicates that media is present e g during imaging 0 indicates the sensor is clear This is the normal operating condition 36 SERVICE MANUAL Replacing the Imager Sensors See Figure 54 2 1 Remove the front panel 2 Access sensors from the front of the Platesetter Disconnect the three pin connector from the Sensor 3 Remove the sensor by removing the two screws holding the sensor in place 4 Install new sensor in reverse order Replace the front panel and clo
58. to avoid getting anything caught between the rollers R RER 2k OK OK kk k OK OK ok ok OK OK OK OK OK OK ok OK ok OK OK OK k k OK OK R R RR R R KOK eek 2 From the Main Menu display on the control panel press 4 and then 1 to access the Run Hardware Menu 3 Turn on the capstan motor by pressing the 2 key and then the ON key Access the rollers from the top of the Platesetter and open the shutter As the pinch and capstan rollers are rotating clean them using a soft cloth and D Ink Press the key to turn off the transport motor then press ESC 4 Press the ESC key again to return to the Main Menu then press the 3 key to return the Platesetter to the on line mode 5 Gently lower the marker and lock by pushing marker lever down until lever is horizontal Close the top cover 64 PREVENTIVE MAINTENANCE Cleaning the Processor Module For optimum performance of the processor module it is important to keep all chemistry filled to the proper levels and clean the machine weekly to prevent a buildup of chemistry on the rollers The processor should be cleaned more frequently if needed to maintain plate quality If you re using Mitsubishi Silver Digiplate the processor should be cleaned if the pH of the chemicals fall outside the recommended range Activator pH 12 8 Stabilizer pH 6 8 To clean the processor see figure 6 1 l Open the top cover Be sure that t
59. 00040 003 806795 001 806796 001 806797 001 900289 003 806810 001 806782 001 806783 001 806826 001 806798 001 900967 004 900968 003 900967 005 901076 003 900338 002 806827 001 806827 002 806830 001 806827 003 806827 004 Revision F Component Description PANEL ELECTRICAL LOWER CLIP CORD ADHESIVE ASSY CABLE HEATER CONTROL ASSY CABLE MOTOR CONTROL ASSY CABLE DRYER HEATER BUSHING GROMMET LABEL POWER SUPPLY ASSY STRIP TSI ASSY STRIP TS2 ASSY CABLE GROUND ASSY CABLE POWER CONTROL SCREW STAINLESS 4 40 X 375 NUT STAINLESS 4 40 X HEX LOCKNUT SCREW STAINLESS 8 32 X 5 PHILLIPS PANHEAD WASHER STAINLESS 8 MOUNT TIE ASSY CABLE JUMPER 3 5 ASSY CABLE JUMPER 4 5 ASSY CABLE PROCESSOR MOTOR ASSY CABLE JUMPER 3 5 ASSY CABLE JUMPER 3 75 Parts List Page 1 of 1 FROM REFERENCE 51 1 P8 1 IS1 1 TS1 4 806827 003 ITEM 27 TS1 2 GND 1 806826 001 ITEM 11 IS1 2 TS1 6 806827 001 ITEM 21 TS1 3 8 3 181 3 P8 4 TS1 4 TS2 3 806827 004 ITEM 28 TS1 4 DRIVE MOTOR 806830 001 ITEM 23 TS1 4 BLOWER FAN MOTOR BLACK TSI 5 P5 1 TS1 5 BLOWER FAN MOTOR BLACK TS1 6 TS2 1 806827 002 ITEM 22 TS1 6 DRIVE MOTOR 806830 001 ITEM 23 TS1 6 BLOWER FAN MOTOR GREEN YELLOW TS1 7 DRIVE MOTOR 806830 001 ITEM 23 TS2 1 Pg 2 1
60. 01072 005 901089 001 806822 001 806694 002 806510 001 901070 001 806819 001 900319 004 807231 007 806695 001 900773 001 900968 005 900215 007 807225 005 Revision A Component Description PLATE STABILIZER FRONT BEARING ROLLER GEAR ASSY GEAR SHAFT IDLER GEAR SPUR E RING SAE 25 SHAFT STUD GEAR GEAR SPUR E RING SAE 312 SHAFT PLATE STABILIZER REAR BRKT DRIVE RACK GEAR WORM SINGLE PIN DOWEL 125 DIAMETER X 625 LONG SHAFT DRIVE RACK ASSY STABILIZER ENTRANCE GUIDE ROLLER TRANSPORT HANDLE RACK ROLLER SQUEEGEE POLISHED ASSY PROCESSOR GUIDE SCREW STAINLESS 8 32 X 375 PHILLIPS PANHEAD WASHER SPRING LOCK STAINLESS 8 055 X 04 WASHER FLAT STAINLESS 10 7 16 X 13 64 X 062 SCREW STAINLESS 10 24 X 375 PILLIPS PANHEAD WASHER SPRING LOCK STAINLESS SCREW STAINLESS TAP FORM 10 24 X 1 ROD SUPPORT SPRING EXTENSION ROLLER PROCESSOR ASSIST SCREW SET STAINLESS 8 32 X 25 GEAR MOD BEARING NON METALLIC FLANGED LABEL GUIDE COVER GUIDE F COLLAR GEAR COLLAR SHAFT NUT STAINLESS 10 24 KEPS LOCKNUT WASHER NYLON 1 4 X 5 X 032 THICK LABEL STABILIZER Parts List Page 1 of 1 Printware Confidential 5 PLACES BOTH ENDS 7 gt Z 5 Mu os b a Sn 3 PLACES BOTH ENDS 2 BOTH ENDS Printware ASSY STABILIZER TRANSPORT 808049 001 REVISION A Sheet of 3 2 SEIS 3 PLACES 7 Es 28 0 p
61. 043 044 045 047 048 049 050 052 Assembly Number 807501 002 ASSY PUNCH COMBO SC Quantity Component Used 1 N N pl NO NO FB N C WO e NO Number 807415 002 901051 005 807460 004 901051 008 900940 003 900940 004 900940 005 900289 003 901053 001 901052 003 807301 001 807616 001 807617 001 807615 001 900235 041 807661 001 901283 001 806935 001 806934 001 807677 001 900236 002 807660 001 806936 001 9003 19 004 807614 002 900570 007 807664 001 900157 008 901187 003 900 160 004 900160 005 90065 1 022 90065 1 020 900047 000 900445 006 900445 007 900236 008 900235 040 900233 003 900233 001 900288 006 900445 004 Revision L Component Description ASS Y COMPRESSOR MODIFIED FITTING TUBE QUICK STRAIGHT ASS Y PUNCH COMBO FITTING TUBE QUICK STRAIGHT TUBING POLYURETHANE RED EA FT TUBING POLYURETHANE ORANGE TUBING POLYURETHANE GREEN BUSHING GROMMET MUFFLER PNEUMATIC SOLENOID AIR VALVE ASSY CABLE SOLENOID PLATE FRONT DEFLECTOR PLATE BACK DEFLECTOR TROUGH PUNCH SCREW SHC 38 32 X 1 1 4 TRAY PUNCH HANDLE PLASTIC TAPERED BRACKET PUNCH MOUNTING NON OPERATOR SIDE 32 BRACKET PUNCH MOUNTING OPERATOR SIDE ASSY PUNCH UPPER GUIDE SCREW SOCKET HEAD SHOULDER 10 32 X 626 ASSY ROLLER PUNCH EXIT BRACKET PUNCH PLATE BEARING NON METALLIC FLANGED ASSY IDLER POST PULLEY TIMING BELT 18 GROOVES ASSY PULLEY SCREW SET CUP POINT 74 40 X 25 BELT TIMING DOUBLE SIDED 195 GROOVE
62. 10 Changing Processor 50 60 HZ I 11 Calibrate Processor I 12 Physical Calibration I 13 Overview 1 13 Cutter Skew 1 13 Transport Skew 1 14 Image Skew I 15 Scan Width and Linearity Adjustment 1 17 Marker Position Adjustment 1 17 Adjusting Image Length 1 18 Adjusting Overlap I 19 Adjusting Cut Length I 19 Adjusting Backup Length I 20 Adjusting Fogging Edge LED I 20 Adjusting Miniplate Backup Length I 21 Punch Alignment and Skew 1 22 Adjusting Punch Length 1 24 Density Dot Calibration 1 25 De Installing the Platesetter 1 26 Serial Numbers and Factory Settings 1 29 PLATESTREAM PLATESETTER INSTALLATION GUIDE Pre Installation Checklist 1 Confirm Electrical Requirements Verify that the electrical power of the required voltage and current is available at the machine location Verify an Ethernet network drop is available at the RIP location The RIP requires a 10 Base T or thin coaxial cable The Platesetter requires a dedicated 200 240 VAC 20 amp 60Hz three wire single phase electrical line The platesetter can be switched to 50 Hz operation A 100 120 VAC 15 amp 50 60Hz line with a power strip is required for the Raster Image Processor RIP The RIP can be switched to 200 240 VAC operation The Platesetter is shipped without a power plug The Platesetter power cord length is approximately 9 The power plug used with the Platesetter must be rated for 20 amp 250 volt power and should have the proper safety certification for the
63. 306 002 40 BLACK GND 40 4 BROWN SPARE 0 41 o 42 RED SPARE 0 42 43 ORANGE GND 43 2 44 YELLOW EX DIR 44 RED 1 24V ORANGE 1 45 EX DIR 45 BLACK FAN DRV WHITE 2 J 2 46 BLUE GND 16 47 VIOLET SPARE 2 47 COOLING FAN 48 GRAY SPARE 2 48 49 WHITE GND 49 CABLE 50 BLACK GND 50 804140 002 WHITE 1 otr NEN ORANGE 2 NU WHITE 3 J 3 1 BROWN NO MEDIA 5V NOOWEDIR 807301 001 ORANGE 2 NO MEDIA SIG SENSOR NO 3 GE NO MEDIA GND CABLE m YELLOW NU 807091 001 807226 001 5 GREEN NU 806099 001 BLUE NU ENTM RON SOLENOID WHITE 24V ORANGE 7 VIOLET NU SHUTTER DRV WHITE 2 8 GRAY NU WHITE 424v ORANGE 3 J5 9 WHITE NU OLENOID WHITE SHUTTER DRV WHITE 4 10 BLACK NU 806099 001 Z ROWN AE CABLE 807204 001 NE WORKING TANKS LOW Y uso 1 15 GREEN NU GND RED 2 16 BLUE NU REPLN TANKS LOW ORANGE 3 17 VIOLET NU GND YELLOW 4 18 GRAY NU EFF TANK HIGH GREEN 5 19 WHITE NU GND BLUE 6 5 20 NU PROC TEMP VIOLET 7 21 BROWN NU GND GRAY 8 22 RED NU FILM EXIT WHITE 9 SENSORS 23 ORANGE NU GND BLACK 10 24 YELLOW NU M DAS 11 22 00 SPARE BROWN 11 25 GREEN NU ENG TO GND RED 12 26 BLUE NU PRINT W ARE INC PROCESSOR 45V PULL UP ORANGE 13 JA 4 27 VIOLET NU SOJ YELLOW 14 28 GRAY NU ST P AUL MN J1 45V PULL UP GREEN 15 29 WHITE NU E MEG 2 DRIVE INH BLUE 16 30 BLACK NU Q A MATERIAL 5V_PULL UP VIOLET 17 31 BROWN NU 5 TOLERANCE UNLESS OTHERWISE SPECIFIEI RESET GRAY 18 32 RED NU
64. 51S s 215 215 51 S 21515 5 5 CABLE iml KAI Koal bau LAJ EON Ganl Gani Dani Gani Gani bani Aani Azai Ammi Ami EXI ESI EAI Aja Kos Koel Roe baa Bnd Be SF ie ie I xml 803318 002 ei 002 wa rr sa wEIAII m rs J1 2 1 BROWN V GND 1 d 2 RED FD STEP 2 SUED C e 36 SUPPLY ima E 4 YELLOW GND 4 DRAWER e OA 5 GREEN FD RESET 5 7 ER EL Ir 2 gt 6 BLUE FD RESET 6 LL BLACK 6 J16 7 VIOLET GND 7 E s 1 BEUE x 8 GRAY TR STEP 8 T HER a Rack 8 5 9 TR STEP 9 olo 7 ORANGE 3 10 BLACK GND 10 oj 11 BROWN TR RESET 11 INTERFACE 12 RED TR RESET 12 13 ORANGE GND 13 14 YELLOW EX STEP 14 15 GREEN EX STEP 15 523060 001 16 BLUE GND 16 x T INTERFACE gt 17 VIOLET EX RESET 17 oje BOARD LAY OUT 18 GRAY EX RESET 18 _ 19 WHITE GND 19 J 1 NU 20 BLACK CUT STEP 20 ES Pe 5 21 BROWN CUT STEP 21 O 22 RED GND 22 ol J11 23 ORANGE CUT RESET 23 TO lt 772 24 YELLOW CUT RESET 24 CND ENGINE STEPPER 26 BLUE PLG OP 26 PCA J7 5 27 VIOLET PLG OP 27 O 5 28 GRAY GND 28 eg 29 WHITE STEP SYNC 29 2 J NU 30 BLACK STEP SYNC 30 _ c e lt 31 BROWN GND 31 32 RED SPARE 3 32 33 ORANGE SPARE 3 33 34 YELLOW GND 34 35 GREEN FD TR DIR 35 i 36 BLUE FD TR DIR 36 5 37 VIOLET GND 37 38 GRAY SPARE 1 38 J 4 NU 39 WHITE SPARE 1 39 2 CABLE 4 O zd e 806
65. 52 1 1S2 6 806827 001 ITEM 21 1S2 2 5 2 152 3 1S2 8 806827 003 ITEM 27 152 3 913 1 192 4 13 2 192 4 p4 2 m TS2 5 P13 3 152 5 P4 3 1S2 6 P13 4 182 7 P4 1 1S2 7 ACT TANK HEATER 182 8 ACT TANK HEATER 23 20 806798 001 Printware Confidential l WwW O 28 806796 001 806797 001 TU BLOWER FAN MOTOR Printware ASS Y ELECTRICAL PANEL 806708 001 REVISION F Sheet 1 of Find Number 001 002 004 008 009 010 012 013 014 016 017 018 Quantity Component Used 1 1 11 BN N e e 44 Assembly Number 808228 002 Number 808229 001 80675 1 001 901077 001 900230 002 806747 001 900229 019 901079 001 806649 001 806649 002 807352 001 807351 001 900005 002 ASSY TRANSPORT DRYER ROLLER FOAM Revision C Component Description RACK PANEL ROLLER FOAM ROLLER DRYER LOWER BELT ENDLESS ROUND BEARING NYLON SNAP IN 25 SHAFT ROLLER DRYER UPPER E RING SAE 375 SHAFT PIN SPIRAL ASSY FLANGED BEARING ASSY FLANGED BEARING SHAFT 19 75 LONG ROLLER FOAM RING GRIP Parts List Page 1 of 1 x AS AR S Y ESSE EII 9 DES o P f E x 4 Z Printware ASSY DRYER TRANSPORT 808228 002 REVISION C Sheet 1 of 1 Printware Confidential Find Number 001 002 003 005 00
66. 6 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 025 026 027 028 029 030 031 032 033 038 039 040 041 042 043 044 045 048 049 050 Assembly Number 806925 002 ASSY PUNCH SC BACHER 220 Quantity Component Used mA mom oU 2 9 9 UN N N UJ N bh e e N A e N c NO N a 1 00 Number 807415 002 901051 005 901051 002 901051 008 900940 003 900940 004 900940 005 900289 003 901053 001 807460 001 901052 003 807301 001 807691 001 807692 001 807615 001 900235 040 807661 001 901283 001 806935 002 806957 001 807677 001 900236 002 900610 003 807660 001 806936 001 900319 004 807614 002 900570 007 807664 001 900157 008 901187 003 900160 004 900160 005 90065 1 022 90065 1 020 900047 000 900445 006 900445 007 900236 008 900233 003 900233 001 900288 006 Revision L Component Description ASS Y COMPRESSOR MODIFIED FITTING TUBE QUICK STRAIGHT FITTING TUBE QUICK UNION TEE FITTING TUBE QUICK STRAIGHT TUBING POLYURETHANE RED EA FT TUBING POLYURETHANE ORANGE TUBING POLYURETHANE GREEN BUSHING GROMMET MUFFLER PNEUMATIC ASS Y PUNCH BACHER 220 SOLENOID AIR VALVE ASS Y CABLE SOLENOID PLATE FRONT DEFLECTOR PLATE BACK DEFLECTOR TROUGH PUNCH SCREW SHC 8 32 X 5 8 TRAY PUNCH HANDLE PLASTIC TAPERED BRACKET PUNCH MOUNTING NON OPERATOR SIDE BRACKET PUNCH MOUNTING OP S
67. 9 001 808044 001 807672 001 900270 003 900233 003 523 190 004 523060 001 90034 1 003 900336 000 900287 007 900257 900222 003 900223 007 900270 009 900270 004 806843 001 807629 001 807624 001 806709 002 806719 009 8073 12 002 806719 008 8073 12 003 8068 15 003 8075 14 001 806866 001 806825 001 901280 001 807625 001 807637 001 807666 001 ASSY IMAGER SC Revision D Component Description KIT FRAME SC PANEL SKIN FRONT PANEL SKIN FEED PANEL SKIN EXIT PANEL SKIN REAR COVER TOP HINGE CONTINUOUS LATCH PULL FLUSH SCREW SHOULDER CAP 8 32 X 5 W ASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 X 375 PLATE NUT 8 32 ASSY TRANSPORT SC ASSY LOWER GUIDE GAS CYLINDER 60 LBS NUT LOCK 8 32 PCA STEPPER SHEAR CUTTER PCA INTERFACE BUSHING SPACER NYLON 6 32 X 375 NUT SELF LOCKING HEX 46 32 SCREW PAN PHILLIPS PANHEAD 716 32 X 75 STUD 10MM BALL 5 16 18 THREAD NUT HEX 5 16 18 WASHER LOCK HELICAL SPRING 5 16 GAS CYLINDER 30 LBS GAS CYLINDER 20 LBS ASSY PUMP BRACKET PUMP MOUNTING ANGLE CORNER ASSY PROBE ASSY TUBE ACTIVATOR ASSY TUBE STABILIZER ASSY TUBE ACTIVATOR ASSY TUBE STABILIZER ASSY PROBE EFFLUENT ASSY INDICATOR LIGHT STOP TRAY ADJUSTABLE PAD RACK CONTAINER SOLUTION LID MODIFICATION PLATE MOUNTING POWER SUPPLY LABEL PLATESTREAM SC LOGO Parts List Page 1 of 2 Assembly Number 808041 001 ASSY IMAGER SC Revision D 86 1 804150 001 TRAY EXIT C
68. AC CABLE 2 3 807521 004 AE A eg eee gt 12 m E RS A EE EA ES Ee S ES ES E ES SEES ES ERES ES ES EE ES ETE ES E eee DC POWER AC POWER WIRECOLOR VOLTAGE 807514 001 RE COLOR RED 5V BEES YELLOW 12V DOMESTIC INTERNATIONAL VOLTAGE BLUE 12V BLACK BROWN AC ORANGE 24V u WHITE BLUE AC WHITE SIGNAL GREEN GREEN YELLOW GROUND BLACK GROUND 14 6 GREEN CHASISE GND 1618 PIN ASSIGNMENTS lt CABLE 807530 001 _ FROM FRONT OF P S DRAWER 1 1 2 2 ma ma ma m zl z z o zl o z o E gag ez eia gaz eia g az gag xz CABLE 807520 002 amp S Ol S Ol S sao ese sas S110 a 51S 2 al oo 6 s 2 me o ESE CABLE 803318 002 kawaka 1 BROWN GND BROWN 1 1 er i ENGINE STEPPER PCA 4 u 2 9 523190 004 WHEEL CUTTER 1 REST 5 J1 NU 3 4 STEP oa TESTER 9 10 BLACK GND BLACK 10 BROWN RESET BROWN ii SCHEMATIC PAGE 5 12 RED TR RESET RED 12 INTERFACE PCA 13 ORANGE GND ORANGE 13 523060 001 14 YELLOW EX STEP YELLOW 14 PAPER FEED 1 TS2 TS1 BROWN 15 GREEN EX STEP GREEN 15 2 L1 POWER SUPPLY 16 BLUE GND BLUE 16 J3 3 Pe 17 VIOLET EX RESET VIOLET 17 n oo 220V SCHEMATIC PAGE 4 18 GRAY EX RESET GRAY 18 L2
69. AGE BLACK BROWN WHITE BLUE GREEN GREEN YELLOW GROUND VENT FAN 900894 001 BROWN POWER SUPPLY INTEGRATED ASSY 808046 TAB CABLE 803321 001 1 RED ENG STP 45V POWER ENG STEPPER PCA G 6 7 BLACK ENG STP GND 4 ORANGE 24V 8 BLACK GND CABLE 803319 002 1 7 RED V CONT 5V 3 YELLOW CONT 12V CONTROLLER 4 BLUE CONT 12V E 6 ORANGE CONT 24V 3 2 5 8 9 10 BLACK CONT GND 12 ORANGE VENT FAN 24 11 BLACK VENT FAN RTN DC POWER SUPPLY 901142 001 ALL FUSES CABLE 807520 002 250V 7A 600322 001 1 2 600267 002 20 RED V INTRE SY INTERFACE SWITCH 45V FUSE 11 YELLOW INTRF 12V OP PANEL CORCOM Se Eu 7 ORANGE INTRF 24V 30VK6 72 6 5 10 19 BLACK INTRF GND 25A 40 F 5 RED 5V 250V BE 5 22 3 J6 08000 4 YELLOW OP 12V 13 BLUE OP 12V 900813 001 ls fr 9 12 BLACK GND WIRE COLOR VOLTAGE RED 5 V J2 NU YELLOW 12V BLUE 12V ORANGE 24V WHITE SIGNAL BLACK GROUND GREEN CHASISE GND J3 NU PROCESSOR AC CABLE DAS 11 22 00 ENG PRINTWARE INC ENG APPVL d ST PAUL MN Q A MATERIAL TOLERANCE UNLESS OTHERWISE SPECIFIEL ANGLES eerie 5 DEG 1 PLACE DECIMALS xin FINISH 2 PLACE DECIMALS 02 3 PLACE DECIMALS 010 PIN ASSIGNMENTS FROM SIDE OF P 5 DRAWER Title WIRING DIAGRAM PlateStream N O DO NOT SCALE DRAWING
70. APTER 1 GENERAL INFORMATION This Platesetter has been certified as a Class 1 laser product under the U S Department of Health and Human Services DHHS Radiation Performance Standard This standard is in accordance with the Radiation Control for Health and Safety Act of 1968 A Class 1 certification means the Imager does not produce hazardous laser radiation Observe proper Electro Static Discharge ESD procedures at all ti mes during maintenance of this equipment especially when servicing the RIP ESD can damage sensitive micro electronic circuitry leading to immediate failure or gradual degradation of performance over time Observing the following precautions will help to prevent ESD damage to components Always keep PCAs in anti static bags during transport or at any time when removed from the ma chine Never lay them down unprotected unless working at a static protected workstation Wear a ground strap attached to your wrist and to the frame of the machine Always keep ESD in mind when working on electronic equipment Use grounded or nonmetallic tools whenever possible Do not attempt to open the inner covers other than described in this manual Be especially careful when working on or around the following areas of the Platesetter Marker Power Supply Assembly Processor SERVICE MANUAL The Platesetter is controlled by a Raster Image Processor RIP several different RIP options are available depending on
71. ATOR REAR SPRING EXTENSION BRACKET DRIVE RACK GEAR WORM SINGLE PIN DOWEL 125 DIAMETER X 625 LONG SHAFT DRIVE RACK ASS Y PROCESSOR GUIDE HANDLE RACK ROLLER TRANSPORT O RING SCREW STAINLESS 8 32 X 375 PHILLIPS PANHEAD W ASHER SPRING LOCK STAINLESS 8 055 X 04 WASHER FLAT STAINLESS 10 7 16 X 13 64 X 062 SCREW STAINLESS 10 24 X 375 PHILLIPS PANHEAD WASHER SPRING LOCK STAINLESS SCREW STAINLESS TAP FORM 10 24 X 1 ROLLER SQUEEGEE POLISHED ROLLER PROCESSOR ASSIST GUARD PROCESSOR SPLASH ROD SUPPORT BEARING NON METALLIC FLANGED SCREW SET STAINLESS 8 32 X 25 GEAR MOD COLLAR GEAR COLLAR SHAFT NUT STAINLESS 10 24 KEPS LOCKNUT WASHER NYLON 1 4 X 5 O D X 032 THICK LABEL ACTIVATOR Parts List Page 1 of 1 PLCS 2 PLUS Printware Confidential lt lt gt 24 2 M M 0 i NA fr lt gt 4 29X6 PLUS Printware ASSY ACTIVATOR TRANSPORT 808048 001 REVISION A Sheet of 3 790 ON o I T e Printware ASS Y ACTIVATOR TRANSPORT 808048 001 REVISION A Printware Confidential Sheet 2 of 3 1 0 OP SIDE 42 7 SEE NOTE 1 WRAP ITEM 11 AROUND xS BOTH BEARINGS 2 PLCS WRAP ITEM 11 AROUND 25 BOTH BEARINGS 2 PLCS Printware ASS Y ACTIVATOR TRANSPORT 808048 001 REVISION A Printware Confidential Sheet 3 of 3 Ass
72. E 49 50 GND BLACK 50 806127 001 1 2 3 4 5 J6 NU 5 7 8 9 CABLE 803321 001 10 11 12 2 V ORANGE 4 SUPPLY DENN DAS 11 22 00 DRAWER ENG PRINTWARE INC 7 GND BLACK 5 stack 3 ST PAUL MN Q A MATERIAL 2 TOLERANCE UNLESS OTHERWISE SPECIFIEI CY ANGLES usa SU 5 DEG I 1 PLACE DECIMALS ai FINISH 2 2 PLACE DECIMALS 02 3 PLACE DECIMALS 010 Q Title Y 2 WIRING DIAGRAM PlateStream SC Z COMM CODE Size INSP VERSION REV 2 FIRST USED ON B 700636 001 A SCHEMATIC PAGE 5 NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 5 of 6 proprietary and may not be used in any manner not consistent with the rights of Printware Inc 6 EXIT SWITCH 600333 001 RIBBON CABLE TO INTERFACE BOARD WORKING TANK SENSORS PS46 806794 001 806800 001 5 807204 001 EFFLUENT TANK LEVEL PS46 806815 001 DRIER TEMP SENSOR MOUNTING SCREW PS 8068 15 002 600330 001 ACT TEMP PROBE 806786 001 REPLENISHMENT TANK SENSORS 806709 001 PINS 1 amp 2 ARE WHITE PINS 3 amp 4 ARE BLACK PINS 2 amp 4 ACT PINS amp 3 STAB WHITE BLACK DRIVE MOTOR PROCESSOR Q 806703 001 2
73. EARING NON METALLIC FLANGED WASHER LOCK HELICAL SPRING 1 4 REGULAR WASHER FLAT STEEL 1 4 REGULAR PLATE BACKING SPOOL 02 PLATE BACKING SPOOL 015 RECEPTACLE SPOOL NUT LOCK 6 32 E RING SAE 625 SHAFT SCREW PHILLIPS PANHEAD 4 40 X 75 NUT LOCK 4 40 SCREW B H TORX 8 32 X 375 W ASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 X 5 WASHER EXTERNAL LOCK 6 SPRING COMPRESSION 1 X 66 X 072 KNOB KNURLED SHC 8 SCREW FLAT HEAD 6 32 X 38 WASHER FLAT STEEL 8 NUT LOCK 8 32 SPRING COMPRESSION 75 X 36 X 042 PLUNGER SPRING LOADED SCREW SOCKET HEAD SHOULDER 8 32 X 6255 SCREW TAPTITE PHILLIPS PANHEAD 8 32 X 5 SCREW SHC 8 32 X 5 SCREW TAPTITE PHILLIPS PANHEAD 6 32 X 3 8 NUT HEX JAM 1 4 X 28 SCREW SHC 8 32 X 5 8 297 298 304 305 306 307 308 312 315 316 317 319 321 322 323 NO m m N 9 QQ WO Lr Assembly Number 808044 001 900160 012 900235 041 807014 002 900257 900223 007 900222 003 900651 019 807231 001 807093 001 807093 003 807093 004 807503 001 806099 002 806099 001 900236 003 ASSY TRANSPORT SMALL COMMERCIAL Revision C W ASHER FLAT STEEL 8 NARROW SCREW SHC 8 32 X 1 1 4 ASSY IDLER POST TRACTION CONTROL STUD 10MM BALL 5 16 18 W ASHER LOCK HELICAL SPRING 5 16 NUT HEX HEAD UNC 5 16 18 WASHER FENDER 434 X 16 X 125 LABEL GUIDE COVER GUIDE A LABEL PLATE GUIDE POSITION LABEL PLATE GUIDE POSITION EDGE
74. ERAL INFORMATION Features Overview The I O panel is located on the top rear of the Platesetter This panel is used to connect the Platesetter to an external RIP The Platesetter images plates at a rate of 40 plates per hour at 2400 DPI Plates emerge right reading for easy proofing and final plate checks The Platesetter can image any width from 9 to 13 3 and any length from 12 to 22 The maximum roll length is 280 The media loading is accessible from the top of the Platesetter providing quick easy loading of plate material The control panel is an applet on the RIP The control panel keys allow you to perform a number of adjustment and diagnostic func tions and the 8 x 40 character display shows status error mes sages and function menus The power switch 1s located in the rear of the Platesetter MiniPlate With this option the Platesetter will impose multiple jobs shorter than the minimum plate length Punch With the PunchStream integrated punch option the Platesetter will automatically punch the plate Infrared With this option the Platesetter will image Infrared 780 nm plate material 1 4 GENERAL INFORMATION Rear 1 0 panel 2 clearance 24 clearance rt 65 12 clearance left O O p Power Switch 29 30 clearance front Figure 1 4 Features of PlateStream Platesetter GENERAL INFORMATION Operator Safety The Printware Platesetter has been
75. HEAR CUTTER 19 5 18 O DECURL EXIT STEPPER BOARD C O LAY OUT CABLE 803318 002 PAPER FEED 10 L GND BROWN B 2 FD STEP RED 2 O 3 FD STEP ORANGE 3 4 GND YELLOW 4 WHEEL CUTTER 5 FD RESET GREEN 5 MARKER TRANS 6 RESET BLUE 6 J1 NU 18 7 GND VIOLET 7 SH E TR STEP GRAY 3 ENGINE STEPPER PCA 9 TR STEP WHITE 9 10 GND BLACK 10 523190 004 POWER 11 TR RESET BROWN 11 12 TR RESET RED 12 m 13 GND ORANGE 13 14 YELLOW 14 PAPER FEED O 15 EX STEP GREEN 15 16 GND BLUE 16 J3 17 EX RESET VIOLET 17 SE 18 RESET GRAY 18 9 19 GND WHITE 19 CAPSTAN STEPPER CUT S 20 CUT STEP BLACK 20 804628 001 DERE 9 21 CUT STEP BROWN 21 9 22 GND RED 22 PF 23 CUT RESET ORANGE 23 MT J7 1 24 CUT RESET YELLOW 24 MARKER TRANS BLACK 803323 002 1 1 INTERFACE PCA J11 25 GND GREEN 25 RED 26 PLG OP BLUE 26 h 27 PLG OP VIOLET 27 EOE E 4 28 GND GRAY 28 29 STEP SYNC WHITE 29 30 STEP SYNC BLACK 30 31 GND BROWN 31 32 SPARE3 RED 32 33 SPARE3 ORANGE 33 34 GND YELLOW 34 DECURL EXIT 35 FD TR DIR GREEN 35 36 FD TR DIR BLUE 36 J2 37 GND VIOLET 37 38 SPAREI GRAY 38 39 SPAREI WHITE 39 40 GND BLACK 40 41 SPAREO BROWN 41 CUTTER ASSY 42 SPAREO RED 42 43 GND ORANGE 43 44 DIR YELLOW 44 SHEAR CUTTER BLACK 1 1 BLACK 45 EX DIR GREEN 45 7 WHITE 46 GND BLUE 46 JS D o aH 3 3 BLACK 47 SPARE2 VIOLET 47 4 RED 4 ED cutter MOTOR 48 SPARE 2 GRAY 48 49 GND WHIT
76. IDE ASS Y PUNCH UPPER GUIDE SCREW SOCKET HEAD SHOULDER 10 32 X 626 V SEAL SHUTTER ASSY ROLLER PUNCH EXIT BRACKET PUNCH PLATE BEARING NON METALLIC FLANGED ASSY IDLER POST PULLEY TIMING BELT 18 GROOVES ASSY PULLEY SCREW SET CUP POINT 4 40 X 25 BELT TIMING DBL SIDED 195 GRV W ASHER FLAT STEEL 6 WASHER FLAT STEEL 8 W ASHER FENDER 5 X 189 X 125 WASHER FENDER 749 X 203 X 156 WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 X 375 SCREW B H TORX 8 32 X 5 SCREW SOCKET HEAD SHOULDER 78 32 X 2505 NUT LOCK 78 32 NUT LOCK 710 32 SCREW PHILLIPS PANHEAD 10 32 X 1 5 Parts List Page 1 of 2 052 053 054 055 056 057 058 060 061 NN NY WN NY Assembly Number 806925 002 ASSY PUNCH SC BACHER 220 900445 004 900047 002 900005 002 900336 000 900445 001 900608 001 900287 025 806127 004 900235 041 Revision L SCREW B H TORX 6 32 UNC X 375 WASHER EXTERNAL LOCK 76 RING GRIP NUT SELF LOCKING HEX 46 32 SCREW B H TORX 1 4 20 X 5 WASHER FLAT 1 4 SCREW PHILLIPS PANHEAD 6 32 X 1 25 ASSY CUTTER 13 SCREW SHC 8 32 X 1 1 4 REF ROLLER ASS Y ON 2 dl A AL VEA YE 5 e d 2 Q coo Ly MM m E Ww NJ REF CHASSIS ASS F CHASSIS ASS Printware ASS Y BACHER PUNCH SC 806925 002 REVISION I Printware Confidential Sheet of
77. LLL LLL LL uu hul ayau 7 7 Clearing Media 7 10 El TOW SCI CS o Om kaa 7 12 Appendix A Specifications A 2 Appendix B Calibration B 2 Appendix C Halftoning and C 2 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION Introduction The Printware Platesetter is a compact high resolution digital Platesetter for a range of small format printing applications Plates are exposed using a patented laser imaging system and auto matically processed Figure 1 1 illustrates a flowchart of the platemaking process The Platesetter is controlled by a Raster Image Processor RIP several different RIP options are available depending on the most common type of work to be done The system is driven by the host computer on which the operator composes the text and graphics to be imaged Once the print job has been composed on the host computer it is sent to the RIP where it is prepared for imaging The rasterized file is then sent to the Platesetter where the file is imaged onto a plate Figure 1 2 illus trates the basic system set up QD o A print Job command is The laser light beam received the media strikes and exposes begins moving around selected areas of the the capstan roller media 4 once the enti
78. NS 4 PLACES Correct processor guide placement Media is being bent in processor Verify that the wire guides are installed properly 2 59 they are easy to put in backwards Verify that the media is coming out of imager module straight Check to see if media comes out of the activator rack straight under the crossover guide Adjust activator stop bracket Short plates jamming in the activator rack One plate comes out of processor and then the messages media did not exit processor and load media both come up SERVICE MANUAL Verify that plate length is within platesetter limita tions 12 or 30 cm minimum Check that the processor wire guides are correctly installed see diagram above for correct proces sor guide placement Verify that the rollers in the activator and stabilizer racks are turning Check processor exit switch in Sensor Status menu Calibrate the processor from Operator Panel 60 SERVICE MANUAL PROCESSING QUALITY PROBLEMS ARTIFACTS Media trailing edge wet Some residual chemistry on the media trailing edge is normal If excessive however follow these steps 1 Verify that the stabilizer tank level is not too high and that the stabilizer drain tube is seated all the way down 2 Check the springs on stabilizer rack squee gee rollers Replace if stretched out 3 Clean squeegee rollers with D Ink and rinse with water 4 Increase dryer hood temperature potenti o
79. PlateStream S TE Platesetter p Click on desired manual Quick Start Guide Installation Guide Operator Manual Service Manual Hlustrated Parts List Printware LEADERS IN COMPUTER TO PLATE 1270 Eagan Industrial Road St Paul MN 55121 Phone 800 456 1400 Fax 651 454 3684 http PrintwareInc com Thumbnails Cote eom JC Platesetter Quick Start Guide Printware LEADERS IN COMPUTER TO PLATE 700631 Rev B QUICK START GUIDE Contents Introduction Loading Plate Material Control Panel Setup Menu RIP Setup amp Imaging Plates QS 2 QS 2 QS 3 QS 4 QUICK START GUIDE Introduction For detailed procedures on the control panel plate media and chemistry preventive maintenance and trouble shooting see the PlateStream SC Operator Manual Before making a plate the Platesetter must be Connected to the RIP the I O connectors are located on the rear of the top cover of the machine Ready to accept a job Main Menu displayed on the control panel On Line state no error conditions The processing tanks must be filled to proper levels Loading Plate Material 1 Open the top cover Raise marker by pulling the marker lever up until lever stops Gently lift up marker If you are replacing the roll of plate media the last of the previouos roll may need to be removed from the platesetter 2 Remove the spool assembly from the Platesetter 3 Adjust the rear e
80. SUPPORT RACK ASSY CLUTCH SHAFT BEARING ROLLER BRACKET CLUTCH BEARING FLANGE MODIFIED BUSHING GROMMET ASSY TEMPEATURE PROBE ACTIVATOR ASS Y LEVEL SENSOR ASSY DRIVE SHAFT ASSY DRYER DRIVE SUPPORT UPPER DUCT RAIL RIGHT GUSSET RAIL DRIVE FRAME DRIVE DRYER BUSHING GROMMET ASSY CABLE P3 TO J14 MOUNT TIE ANCHOR NYLON SWITCH WIRE FORM SWITCH SNAP LEVER DUCT VERTICAL ASSY STABILIZER TRANSPORT SC ASSY ACTIVATOR TRANSPORT SC ASSY ACTIVATOR TANK ASSY STABILIZER TANK RAIL LEFT MOUNT TIE ASSY CABLE ACT STABILIZER LEVEL ASSY CABLE INTERFACE 13 SENSOR THERMISTOR DISK SHIM SUPPORT RACK PROCESSOR ASSY HEATER COVER ASSY HEATER BLOWER ASSY CABLE DRY TEMPERATURE PROBE ASSY CABLE FILM SWITCH ASSY CABLE REPLENISHMENT LEVEL PCA INTERFACE PROCESSOR ASSY ELECTRICAL PANEL ASSY DRIVER MOTOR BELT TIMING 1 5 PITCH 60 GROVES PANEL PCA BOARD SCREW STAINLESS 10 24 X 5 BLOCK SUPPORT SWITCH Parts List Page 1 of 2 051 052 053 054 055 056 057 059 060 061 062 063 064 065 066 067 068 069 074 075 076 079 089 102 103 106 107 UJ Us a N e e Ne me e me e G NO CO O gt O b Assembly Number 808047 001 ASSY PROCESSOR PLATESTREAM SC 901089 004 900967 003 901072 005 900968 005 900967 006 901072 006 901092 001 900967 007 900967 001 901071 010 900967 005 900337 000 900968 001 900967 019 901076 003 901091 001 901071 012 807394 001 807313 002 808228 002 806848 001
81. UAL REGISTRATION AND SKEWING Image length incorrect 1 Runa Printware Grid18 from the RIP Check to too long or too short be sure scaling in RIP is set at 100 Then mea sure 2 If source of problem is the platesetter errors of less than 250 6 mm can be corrected with the Opera tor Panel length adjustment procedure see Opera tor Guide Image width incorrect 1 Runa Printware Grid18 from the RIP Check to too wide or too narrow be sure scaling in RIP is set at 100 Then mea sure NZ 2 If the source of problem is the platesetter errors of less than 1 8 3 mm can be corrected by realigning the SOS and SOT sensors First plate after a 1 Check loading and guide positions load misregistered on 2 Consider sending blank or test plates before color process color jobs jobs to eliminate first plate skew 44 SERVICE MANUAL REGISTRATION AND SKEWING cont Tracking or skewing problems 1 Adjust roller spring tensions Tools required tension gauge pull gauge or NZ fish scale 1 1 Attach a 2 wide 50 mm strip of thin 0 004 or 0 005 0 1 mm polyester media to the gauge Slide the strip between the roller pair to be tested and measure the force required to pull the media strip out of the roller pairs force should be the same from side to side 1 2 Adjust roller tensioner screws on either side of the roller pairs to set correct tension Correct roller tensions are as follows Fi
82. UE PRN D5 32 RED LASER 1 27 VIOLET PRN D6 14 Ed BLACK GND 2 28 GRAY PRN D6 33 803280 001 IR BLUE 12V 3 29 WHITE PRN D7 15 807220 TAB RED BLACK GND 4 30 BLACK PRN D7 34 BROWN PHOTODIODE 5 FIRMWARE U76 CONTROL HARDWARE 3l BROWN PRN R W 16 BLACK GND 6 U43 PIXEL RATE 32 RED PRN R W 35 U196 ENGINE PROCESSOR 33 ORANGE PRN STRB 17 U199 SCAN PROCESSOR 34 YELLOW PRN STRB 36 35 GREEN PRN ACK 18 36 BLUE PRN ACK 37 GREEN G DRVO 1 37 VIOLET PRN GND 19 GALVO ASSY WHITE G SENSE 2 38 GREEN G DRVI 3 CONNECTORS NOT USED 39 RED G DRVO 4 J2 15 J15 J16 AND SPARE 40 NC BLACK G SENSE 5 RED G DRVI 6 807049 001 RED SOS C 1 SENSOR ASSY GREEN SOS SIG 2 WHITE SOS REF 3 RED SOT C 4 WHITE SOT SIG 5 GRAY SOT REF 6 807151 001 807521 004 e sl e x Le a E E ES ES E Su a Ea ES S ER ERES ES ES Fe ES EE ERES ERES EE E EAE p DAS 11 22 00 ENG PRINTWARE INC ENG APPVL gt ST PAUL MN Z MATERIAL 5 TOLERANCE UNLESS OTHERWISE SPECIFIEL CY ANGLES dodo 5 DEG I 1 PLACE DECIMALS sss FINISH 2 PLACE DECIMALS 02 ie E M ie M ie E M O E M O E A 3 PLACE DECIMALS 010 z SERRE JE SERRE iE z ga ama 3 S 2 S12 8 22 2 3 S 81 S 212 2 2 2 19 2 21 S 21812 212 9 2 lt Z ree Ei
83. ULDER 10 32 X 626 V SEAL SHUTTER ASSY ROLLER PUNCH EXIT BRKT PUNCH PLATE BEARING NON METALLIC FLANGED ASSY IDLER POST PULLEY TIMING BELT 18 GROOVES ASSY PULLEY SCREW SET CUP POINT 74 40 X 25 BELT TIMING DOUBLE SIDED 195 GROOVE WASHER FLAT STEEL 6 WASHER FLAT STEEL 8 WASHER FENDER 5 X 189 X 125 WASHER FENDER 749 X 203 X 156 WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 X 375 SCREW B H TORX 8 32 UNC X 5 SCREW SOCKET HEAD SHOULDER 28 32 X 2505 SCREW SHC 8 32 X 5 8 NUT LOCK 78 32 NUT LOCK 710 32 SCREW PHILLIPS PANHEAD 10 32 X 1 5 Parts List Page 1 of 2 052 053 054 056 057 059 070 N NY r2 L Assembly Number 806926 002 ASSY PUNCH SC PINBAR 900445 004 900047 002 900005 002 900445 001 900608 001 900287 025 806127 004 Revision T SCREW B H TORX 46 32 X 375 WASHER EXTERNAL LOCK 6 RING GRIP SCREW B H TORX 1 4 20 X 5 WASHER FLAT 1 4 SCREW PHILLIPS PANHEAD 6 32 X 1 25 ASSY CUTTER 13 REF REF RDLLER ASSEMBLY F CHASSIS ASS Printware Confidential RANGE INTO TAPPED HULES IN CHASSIS LACE IN HASSIS Printware ASSY PINBAR PUNCH SC 806926 002 REVISION S Sheet 1 of 1 Find Number 001 002 003 005 006 007 008 009 011 012 013 014 015 016 017 018 019 020 021 022 024 026 027 028 029 030 031 032 033 038 039 040 041 042
84. UMP PRIME BLACK 20 32 NU TOLERANCE UNLESS OTHERWISE SPECIFIED 21 BROWN 45V PULL UP BROWN 21 33 ORANGE NU a ANGLES 5 DEG 34 YELLOW NU E e FINISH 1 35 GREEN NU a 2 PLAGE DEGIMATS 02 2 24 YELLOW NU YELLOW 24 36 BLUE NU 5 3 PLACE DECIMALS 010 3 37 VIOLET GUIDE B 45V Title GUIDE B o W G 1 4 26 BLUE NC BLUE 26 38 GRAY GUIDE B SIG SENSOR NO IRIN DIA GRAM P ateStream S 39 WHITE GUIDE B GND NU J13 40 BLACK NU 807091 001 COMM CODE Size 7 00 63 6 001 INSP VERSION REV FIRST USED ON B u A This document and information it contains is the property of Printware Inc and may not be malol shal olol E El E Ed EE S MA I AG 1 a reproduced copied disclosed to others or disposed of directly or indrectly without authoriza SCALE NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 1 f 6 proprietary and may not be used in any manner not consistent with the rights of Printware Inc Re 9 1 2 3 4 5 6 7 8 TAB BLOCK PART NO DESCRIPTION 807046 001 NORTH AMERICAN 807046 501 INTERNATIONAL 806420 003 FOR NORTH AMERICAN USE BLACK WHITE GREEN WIRE 806420 004 FOR INTERNATIONAL USE BROWN BLUE GREEN YELLOW WIRE AC IN Be 240 VAC 50 60HZ 806420 TAB AC POWER WIRE COLOR DOMESTIC INTERNATIONAL VOLT
85. Units English ON ESC OFF ENTER Setting laser power setup menu item 3 40 SERVICE MANUAL EXPOSURE PROBLEMS cont Uneven density from l center to edges amp s 22 1 Hazing on fine print or fine lines 2 3 Going around in circles 1 adjusting laser power 2 4 Calibrate densities Customized firmware can correct slightly uneven density profiles Send several half black half white sample plates from the Operator Panel test plate menu at the resolution of interest to Printware Refocus marker Verify that exposure 1s set correctly by checking Increase laser power Turn laser fogging circuit up turn potentiometer clockwise 60 or 10 minutes Note original potentiometer position If resetting does not alleviate problem return to original position Note that increasing laser power on plates increases density in black non image areas and decreases line thicknesses Use the following typical Operator Panel laser power settings as a sanity check Typical laser power setting RED INFRARED 2400 DPI 35 55 20 30 SERVICE MANUAL IMAGE QUALITY PROBLEMS ARTIFACTS Thin line artifacts Scan lines Vertical artifacts N Ensure laser exposure 15 set correctly Traction control if installed may be jumping This causes irregular horizontal lines 2 1 Increase the belt tension by wrapping the spring around one additional turn 2 2 Temporaril
86. ace the activator and stabilizer racks and tape them down Replace Guide D Bubble wrap cover E guide F and overflow tubes and tape to the top of the working tanks 4 Package Carts a Remove probes from plastic replenishment containers air blow dry and place them in the plastic clip located up underneath the processor section b Empty tanks per local environmental codes Individually bubble wrap the tanks Place tanks in accessory box Remove optional 6 long 1 4 diameter 180 cm by 3 2 cm vinyl hose from underneath the processor Place in accessory box l 26 INSTALLATION GUIDE B Package the marker l 27 Disconnect cables a b Lift the imager top cover Disconnect the grounding strap from the imager section frame Disconnect the 10 wire connector from J6 on the printed circuit assembly PCA located on top of the laser marker assembly d Disconnect the ribbon cable s from J on the PCA and J9 on the PCA Bubble wrap the ends of the disconnected cables Prepare to remove marker a b Raise marker by releasing marker lever and lifting the front of the marker Place a 21 by 1 53 cm by 2 5 cm piece of tape black electrical on the bottom of the laser marker over the slot for the laser light Detach the strut on the laser end while holding the marker in the upright position and removing the cap and pulling strut off the ball joint d Fasten C shaped bla
87. affected by the AC line frequency 1 Unplug the power cord 2 Remove the wire tray located on the right side of the Platesetter Remove the right panel Remove the front cover 3 Remove the drive motor by unscrewing the three screws holding the drive motor to the chassis Discon nect the two drive motor leads and unfasten the motor ground wire Take the drive belt off of the drive shaft by rotating the shaft and deflecting the belt off of the pulley Take care not to damage the wiring Remove the drive gear from the drive motor by loosening the two hex set screws in the gear 4 Remove the driven gear from the drive shaft worm gear by loosening the two hex set screws in the gear Slide the gear off of the drive shaft worm gear while pushing the shaft to the left This allows the gear to clear the opening in the sheet metal 5 For 60 Hz installation the smaller gear 18 Teeth goes on the drive motor and the larger gear 20 Teeth goes on the drive shaft worm gear For 50 Hz installation the larger gear 20 Teeth goes on the drive motor and the smaller gear 18 Teeth goes on the drive shaft worm gear 6 When installing the gear on the drive shaft worm gear move the shaft all the way to the right Center the gear in the sheet metal slot Tighten the two set screws Make sure that one of the screws is on the flat of the shaft 7 When installing the gear on the drive motor push the gear onto the shaft leaving 0 04 1 mm between the ge
88. alibration Manager allows you to create and edit calibration sets and to enable or disable particular sets Atron Edt Previews Color Output Forts Calibration Dot Gain Manager displays calibration sets grouped by device When you select from the Device drop down list all of the existing calibration sets for that device are displayed The basic calibration steps are as follows see the RIP manual for detailed procedures 1 Select Print Calibration to print an uncalibrated target see Figure 2 B 4 ALIBRATION aa eee ma lA A pa E O m mm mam E ee mu i a ll B m m K a TA E Figure 2 Calibration Target 2 Measure the density of each square of the target with the densitometer Note that the densities marked on the target are reversed e g the 10 square will be marked 90 Tip Some densitometers require special procedures to measure densities of less than 1096 consult your densitometer manual 3 Click New to create a new calibration set for the first time The RIP manual describes how to use all the items in the Edit Calibration dialog box but the essential items are as follows e setthe PlateStream for negative right reading set Measurements as negative dot Check Negative media for film plate material is positive media Check Force solid colors indicating that the Plat
89. anual Construction and Function of the Marker Assembly Unit The marker assembly unit consists of a frame top cover lower cover laser lens assembly galva nometer reversing mirror spherical mirror folding mirror SOS sensor and SOT sensor The laser diode produces red or infrared light and is highly sensitive to ESD damage The galvanometer resonates at 540 Hz in a sealed vacuum chamber The marker assembly unit is mounted in an outer frame which is attached by two hinge assemblies to the Imager section chassis The controller PCA is mounted on the top of the marker assembly unit There is a lithium battery backup RAM on the controller printed circuit board U178 on 522980 XXX located on the top of the assembly This RAM lithium battery is not field replaceable Refer to the PlateStream Platesetter Installation Guide for the installation of a new marker When a new marker assembly unit is installed in a Platesetter the new marker assembly unit calibration settings must be stored in the non volatile SRAM memory by the controller PCA This section describes the calibration setting storing procedures Recalibrating the Marker Controller PCA At the main menu press 4 to access the More Information menu Press 2 to access the Calibrate menu Press 2 to calibrate Marker The control panel will display are you sure Pressing ESC exists this menu without changing the marker calibration Pressing ENTER will cause the contr
90. ar Side Operator Side front of Platesetter G T Figure I 9 Image Skew Laser marker assembly too high in front diagonal D E diagonal C F Turn adjustment screw clockwise to correct Leading Edge UJ UN Open Top Cover Marker Assembly Fixed point f ler Capstan Roller U Media E MN Frame Rear Side Front Operator Side Operator Side front of Platesetter G mum Figure I 10 Image Skew Laser marker assembly too low in front diagonal D E diagonal C F Turn adjustment screw counterclockwise to correct INSTALLATION GUIDE Scan Width and Linearity Adjustment Leading Edge This procedure enables you to fine tune the imaging accuracy and the positioning of the laser beam The B overall width of the image on the plate is determined by the positions of two sensors accessible from the front operator side of the laser marker assembly These sensors are called the Start of Trace SOT and Start of Scan SOS sensors The SOT sensor controls the total width of the laser scan which 15 wider than the maximum media width SOS provides the timing reference which starts the active portion of the laser scan across the media Adjusting these two sensors controls the scan width and linearity of the laser marker assembly The sensors are accessed through a small hole in the front of the laser marker asse
91. ar and the motor housing Tighten the two set screws Make sure that one of the screws is on the flat of the shaft Seat the belt onto the driven gear and motor gear while twisting the motor into position Reinstall the two drive motor leads motor ground wire and 3 drive motor screws 9 Reconnect the power cord 9 Turnon the Platesetter From the operator panel start the processor press 4 1 8 Observe that the belt and gears are rotating properly From the operator panel reset processor press 7 Switch off the Platesetter power 10 Replace the panels and wire tray I 11 INSTALLATION GUIDE Calibrate the processor from operator panel This calibration checks to see how long it takes the leading edge of a plate to get to the exit switch of the processor This allows the Platesetter to properly detect a jam condition 1 Load the plate material 2 From the operator panel calibrate the processor press 4 2 1 1 enter A plate will run through the processor 3 From the operator panel press esc esc esc to return to the main menu Rack Drive Gear Drive Motor Belt Drive Shaft Worm Gear Figure 1 3 Inside view of the Processor module Heater Element PROC PAT Switch Drive R42 R43 i Motor 04 Processor N PCA Screws Blower Figure I 4 Right side view of the PlateStream 46 Platesetter 1 12
92. at the amount is sufficient GUIDE Indicates the presence of media at Guide B A 1 indicates that media is present e g during imaging A 0 indicates the sensor is clear This is the normal idle condition WRKNG TANK LOW This sensor monitors the chemistry level in the working tanks in the processor A 0 indicates the current level is okay a 17 indicates a low solution level in one or both of the tanks REPLN TANK LOW This sensor monitors the solution level in the replenishment tanks A 0 indicates the current level is okay 1 indicates a low solution level in one or both of the tanks EFL TANK HIGH This sensor monitors the level of spent solution in the effluent tank A 0 indicates the current level is okay a 1 indicates the tank needs to be emptied PROC TEMP OK The processor Activator Temperature sensor monitors the temperature of the Activator bath A 0 indicates that the current temperature is okay a 1 indicates that the bath is still warming up or that there is a problem with the heater PROC EXIT Indicates the presence or absence of media at the processor exit sensor A 1 indicates that media is present e g during imaging A 0 indicates the sensor is clear This 15 the normal operating condition 2 15 PREPARING FOR OPERATION 3 1 PREPARING FOR OPERATION CHAPTER 3 Preparing to Make Plates Overview The follow
93. ce Carefully follow instructions for the mix and use of chemistry Ink and press chemistry must be compatible Keep all solutions filled to the proper levels Handle plate media carefully Mount plates on the press properly Operator Maintenance Schedule 1 Follow the Printware Recommended Periodic Maintenance Schedule in the Service manual PREVENTIVE MAINTENANCE Maintenance Procedures Cleaning the Imager Rollers Clean all the Imager capstan rollers when necessary to prevent plate slippage or plate skew It s easiest to clean the rollers just after the spool has run out of media To clean these rollers 1 Open the top cover Raise the marker by pulling marker lever up until lever stops Lift up marker gently see Figure 6 1 Marker zm Marker Capstan Roller Pinch Roller 52 Pinch Roller Media Path 4 Cutter Optional Punch Media Input Spool Input guide A Exit guide B Media Path Dryer Exit guide Cover E Processor Working Cover E Guide F o 799 22 O O O Stabilizer Activator Tank Tank Figure 6 1 Side View of the PlateStream Platesetter PREVENTIVE MAINTENANCE K K K K K K K K K K KK K CAUTION Be very careful when working on or around the Imager rollers with the machine running especially when wearing a tie or loose fitting sleeves
94. ce as compared with previously output plates or ones that may be output later 6 Gently lower the marker and lock down by pushing the marker down until the lever is horizontal Close the top cover 7 Set the plate width from the control panel setup menu Load media from the control panel Image one test plate from the control panel Test Plate menu QS 2 QUICK START GUIDE Control Panel Setup Menu EMULSION IN MEDIA Right Hub Position 13 Figure QS 1 Loading Plate Media on Spool The control panel Setup Menu below lists fixed and changeable options for changing various Platesetter parameters ESC to exit Image Reading Resolution 800 DPI Masc Power 55 Media Width 13 12 Spool Pos 13 Input Spool A Destination Processor Display Units English ON ESC OFF ENTER 1 Image Sets the type of imaging The choices are Positive or Negative Wrong Reading and Positive or Negative Right Reading The default is Negative Right reading for plate media 2 Resolution Preset at 2400 DPI 3 Image Power Sets the image power laser intensity 4 Media Width xx xx Spool Pos yy Media Width is the exact width entered by the operator from 7 00 to 13 40 17 78 cm to 34 00 cm Spool Pos indicates the position to set the spool or cassette Spool position 1s set at the media width in inches rounded to the nearest inch from 7 to 13 5 Input Spool Specifies t
95. certified as a Class 1 laser product under the U S Department of Health and Human Services DHHS Radiation Performance Standard This standard is in accordance with the Radiation Control for Health and Safety Act of 1968 A Class 1 certification means the Platesetter does not produce hazardous laser radiation The laser light produced inside the Platesetter is completely confined within protective housings and external covers The laser beam cannot escape from the Platesetter during any phase of user operation provided the user follows the operating instructions specified in this manual A warning label is attached to the bottom of the laser marker unit This label is visible whenever the media path hood is open The Center of Devices and Radiological Health CDRH of the U S Food and Drug Administration implemented regulations for laser products on August 2 1976 Compliance is mandatory for prod ucts marketed in the United States Always follow these basic safety rules when using the Printware Platesetter Read this manual before using the Platesetter 2 Do not remove protective housings or external covers except as specified in this manual 3 Do not disassemble the Platesetter or try to repair it yourself other than as specified in the Preventive Maintenance and Troubleshooting sections of this manual Call an authorized service technician for necessary repair 4 Plug the power cord into a 3 conductor grounded earthed outlet
96. ces ft 120 ml M Mitsubishi Silver DigiPlate Activator 0 47 ounces ft 150 ml M Stabilizer 0 63 ounces ft 200 mI M2 Average Plate Size 0 6 ft 0 8 ft 1 0 ft 12 ft 1 4 f 1 6 fe 1 8 f 2 0 f 2 5 ft 0 00M2 0 07M 0 09 M 0 11 M 0 13 M 0 15 M 0 17 M 0 19 M 0 23 M Printware SilverStream Activator amp Stabilizer oz Activator amp Stabilizer ml Agfa Setprint Plus Activator amp Stabilizer oz Activator amp Stabilizer ml Mitsubishi Silver DigiPlate Activator ounces Stabilizer ounces Activator milliliters Stabilizer milliliters 4 If more replenishment is required turn the screw on the pump clockwise if less replenishment is required turn the screw counterclockwise The screw for the stabilizer replenishment is located towards the front of the pump the screw for the activator is located towards the back of the pump The adjustment screw has a ten turn range 5 If the average plate size changes the replenishment rate should be adjusted 1 10 INSTALLATION GUIDE Changing Processor for 50 60 HZ Operation Note The processor should be properly configured at the factory This procedure is included for refer ence only Refer to figures I 3 and I 4 The AC motor that runs the Processor will run 5 6 of the speed at 50 Hz than at 60 Hz The Processor speed can be adjusted by changing the drive and driven gears in the processor The motors in the imaging section are microprocessor controlled and are not
97. cessive touching of the surface of the media eStore media rolls upright on end not on their sides eTo prevent the crushing of media avoid placing other objects on top of the media rolls eStore all media as recommended by the manufacturer ePlate material will absorb moisture in humid environments and lose moisture in dry environments which will affect print quality However the plate material may not be permanently damaged Improperly stored plate material will recover if stored for an extended period with the bag open in ideal humidity conditions eFor optimum print quality use only recommended media Do not load media that is wrinkled or torn Processing Chemistry eUse only recommended processing chemistry eCarefully follow all label instructions for mixing and use e After use recap activator and stabilizer solution bottles tightly eStore all chemicals in a well ventilated area Follow the manufacturer s instructions regarding safety storage temperature humidity and other environmental factors eRotate supplies to use the oldest items first eDisposal of all chemicals must meet local environmental codes 5 4 CHAPTER 6 PREVENTIVE MAINTENANCE Introduction To avoid problems with the Platesetter maintain high print quality and to avoid unnecessary service calls follow the instructions in this chapter Keep all equipment clean and well maintained Perform regularly scheduled preventive maintenan
98. check media path See chapter 7 Clearing Media Path See chapter 7 Clearing Media Path 1 Ensure that plate media is properly loaded 2 Clean the rollers see Chapter 6 3 Replace the plate material IN CASE OF TROUBLE PROBLEM White Black or Silver Streaks on the Plates Brown Haze on Plates Wet Plates SOLUTION 1 Clean processor and replace chemistry 1 Clean processor and replace chemistry 2 Clean the processor rollers 1 Check that the dryer is functioning 2 Check that the dryer temperature is approx 110 F Adjust if necessary 3 Clean the dryer 4 Clean the processor and replace the chemistry IN CASE OF TROUBLE Clearing Media Path 1 Open the top cover Raise marker by pulling marker lever up until lever stops Gently lift up the marker see Figure 7 1 2 Remove imager front panel 3 Inspect media path for jammed media in the areas described below Access the media path through the top and front cover of the Platesetter Guide A Capstan Guide B Guide C Guide F Cover G Examine infeed section for jammed media Inspect capstan roller for media wrapped around it Open the shutter if necessary The shutter is located on top of the capstan roller Examine this exit guide for jammed media Examine this exit guide for jammed media Remove cover E Slide Guide F toward the rear of the Platesetter Lift the front end of the guide and remove Use the han
99. ck shipping support to the laser right end of the marker with eight screws Detach the strut from the galvo left end of the marker Reattach cap to struts Remove marker a Place blue plastic bag and two DESI PAK bags in the marker assembly carton with the bag laid open b Remove the marker from the Platesetter using two people Slide the marker assembly off the brass pivot bushing located furthest from the processor section left without moving the bushing Slide the marker assembly off the brass pivot bushing located closest to the processor right without moving the bushing Place marker in carton a Place the marker assembly in the blue plastic bag with the laser end placed in the location shown on the drawing that is attached to the bottom of the carton b Fold the blue plastic bag around marker and tie wrap shut Place flat cardboard cover with the four Styrofoam pieces facing up over the plastic bag Seal the carton Bubble wrap and tie wrap the struts inside the Platesetter INSTALLATION GUIDE C Package Platesetter 1 Remove Accessories a Remove wire tray located on the right side of the Platesetter Bubble wrap tray and place in accessory box b Remove customer supplied power plug Bubble wrap the end of the power cord c Remove the media spool assembly Bubble wrap the media spools media shaft individually Place items in accessory box 2 Close the Platesetter top cov
100. country of use The electrical wiring color codes are North America International e Line Black Brown e Neutral White Blue e Ground Green Green Yellow Verify that an electrician 1s available 1f needed 2 Confirm Supply of Recommended Consumables Have at least 16 gallons each of working Activator and Stabilizer on hand Have plate media available as required Plate media may be either paper or polyester based Roll width may be from 7 to 13 4 17 8 cm to 34 0 cm The maximum roll length is 280 85m 3 Confirm Arrival of the Platesetter Verify the machine will be at the installation site final location loading dock storage area etc before scheduling installation The Platesetter should be initially installed by an authorized service technician Recommended Supplies RECOMMENDED CONSUMABLES FOR PLATESTREAM PRINTWARE SILVERSTREAM RED LIGHT PLATE MEDIA Emulsion In 5 mil polyester 808555 XXX 280 FT ROLLS 8 mil polyester 808666 XXX 280 FT ROLLS Note XXX specifies the specific roll width from 7 to 13 4 CHEMISTRY ACTIVATOR 808777 001 STABILIZER 808777 002 INSTALLATION GUIDE 4 Verify Final Location Select a suitable place for installation Avoid excessive dust vibration and direct sunlight The Platesetter is designed for use in a prepress environment Acceptable ambient temperature range is 65 F to 80 F 18 C to 27 C and acceptable relative humidity is 45 to 70 Check the nec
101. dge guide inside the Platesetter by pulling the edge guide knobs out and sliding to the position closest to the plate media width Adjust the front edge guide by loosening the screws and moving the guide all the way to the front 4 Adjust the left hub on the spool shaft to match the edge guide position by squeezing the clip and sliding on shaft Remove the right hub from the shaft by lifting clip and sliding off the shaft Slide media onto shaft Slide the right hub onto shaft by lifting clip and pushing down on spool until spool is tight against media see Figure QS 1 5 Place the spool assembly back onto the receptacles in the Platesetter Feed media through rollers and two edge guides Adjust the front edge guide by turning edge guide knob counterclockwise and sliding edge guide until edge guide rests against plate media Lock edge guide by turning knobs clockwise Feed the media by hand up to the nip of the capstan roller and engage hold down the load switch for approxi mately 5 seconds Watch so that the feed side of the capstan roller picks up on the media and begins to transport it After the media has fed past the exit side pinch roller release the load switch Manually turn the exit side pinch roller approximately 2 revolutions counterclockwise to remove the loop which may have formed over the capstan roller during the load This last step will help the registration of the first few plates output from the platesetter after this load sequecn
102. dle to remove 3 After locating the area of the media jam cut the media from the operator panel Run Hardware Menu 4 Remove all loose media in the Platesetter 4 If media is wrapped around the capstan roller back up the transport rollers from the operator panel More Information Menu 4 To stop the transport roller press the ESC or OFF key 5 Replace all guides to the original positions Gently close the marker and lock it by pushing down the marker lever Reload the plate media 7 10 IN CASE OF TROUBLE Marker Ex Marker 2 Capstan Roller X lt Pinch Roller 4 Cutter 4 Optional Punch Media Input Spool Input guide A Exit guide Media Path Dryer Exit guide Cover E Processor Working Cover E Tus Guide F O oO gt foco O O Activator Stabilizer Tank Tank Figure 7 1 Clearing Media Path 7 11 IN CASE OF TROUBLE Calling For Service Overview To avoid most problems keep equipment clean and follow directions on all imaging and printing supplies Attempt to resolve the problem before calling for service Use the procedures and troubleshooting guidelines outlined in this manual If the problem still cannot be resolved then follow the procedure outlined below Also call on an authorized service technician to perform preventive maintenance as
103. e e Press 1 Calibrate Transport Adjusting Cut Length 1 Measure the distance between points C and D see Figure 1 13 2 If the distance between C and D is gt 0 5 1 27 cm decrease the value for Cut Length Adj on the control panel by the difference for example if the measured value is 0 505 and Cut Length Adj is set at 1 955 then decrease Cut Length Adj to 1 950 LE LLLI LL LLL LLL EERE AEE LLL LLL LL PP IP pp LE LLL TTT pr pp 1 E LL E TTT TT pp 1 LL E LLL LLL LLL pp ELLE Pp pr pp L TTT TT TTT TT TT yy LLL LLL TET TT TT TTT Ey PLT TEE TET ET EEE ey et Operator Side front of Platesetter 3 If the distance between C and D is lt 0 5 1 27 cm increase Cut Length Adj by the difference Figure I 13 Adjusting Cut Length and Backup Length 19 INSTALLATION GUIDE Adjusting Backup Length 1 Measure the distance between points A and see Figure 1 13 2 If the distance between A and B is gt 1 200 3 05 cm increase the value for Backup Length Adj on the control panel by the difference for example if the distance between A and B 15 1 250 and Backup Length Adj is set at 1 350 increase Backup Length Adj to 1 400 3 If the distance between A and B is lt 1 200 3 05 cm decrease Backup Length Adj by the difference 4 Recheck overlap by measuring the width of the black band at the leading edge of the p
104. e Q Check lubricant level in optional punch compressor When the compressor is running the sight glass should be half full Add Printware part number 901176 002 lubricant up to the half full mark if low Note Clean the filter in the filler cap with isopopyl alcohol Dry thoroughly before replacing 2 Processor section maintenance Weekly Q Remove Activator and Stabilizer racks Clean racks and guides with warm soapy water Do not use alcohol or solvents Clean any splashed chemistry from processor and dryer area Inspect racks for worn or damaged components gears and replace as necessary Q At 4 000 plates or 4 weeks whichever comes first completely drain Activator and Stabilizer tanks and clean tanks and racks Refill with fresh chemistry Note Replenishment rates are to be set to Printware recommendations See Setting Replenishment Rates in the Installation Guide Q Check the temperature of the Activator bath 86 F 2 3 Semi annual Preventive Maintenance Performed by Printware authorized service technician Includes check and adjustment replacement as necessary of sensors and belts all bearings gears rollers and clutches pumps blowers motors O rings heater tem peratures marker focus calibration etc SERVICE MANUAL Procedures to Raise and Lower the Marker Open the imager top cover and raise the marker by pulling marker lever up until lever stops Lift up marker gently Lower marker by ge
105. e laser controller board U17 on 522980 XX X mounted to the top of the laser marker unit This lithium battery is not replaceable Dispose of or recycle all printed circuit boards properly WARNING Performing procedures adjustments or using controls in a way other than those specified in this manual can cause hazardous laser radiation exposure electrical hazards or damage to the Platesetter CONTROL PANEL CHAPTER 2 The Control Panel The control panel is an applet that runs on the RIP The control panel program starts automati cally when the RIP is powered up Figure 2 1 illustrates a flowchart of the control panel menus The panel consists of an 8 x 40 character display which shows status messages and menu options and the following 18 keys an ON key an OFF key an ESC key an ENTER key 4 arrow keys 10 numeric keys numbered 0 9 These keys allow you to perform a variety of functions To select an item move the cursor over the corresponding numeric key with the mouse and push the left mouse button to press the key To scroll through the choices of the selected item press the ON or keys To change numbers in a selected item press the numeric keys or press the ON to increase the number and press the OFF to decrease the number To exit a selected item without saving changes press the ESC key To save changes to a selected item press the ENTER key If
106. e the recommended fountain solution ture is incorrect or too properly mixed weak 3 The press ink is not com 3 Use the recommended ink patible with the other chemicals 4 The press dampener 4 Adjust the pressure form roll pressure is out of adjustment 5 The press Moleton cover 5 Replace the cover or sleeve or sleeve is contami nated 6 The Platesetter Processor 6 Replace Platesetter Processor chemistry chemistry is depleted IN CASE OF TROUBLE PROBLEM CAUSE SOLUTION Image Binding faint 1 The press ink fountain bal 1 Check the balance and correct reproduction ance is incorrect if necessary 2 The press pressure is insuf 2 Check the pressure and cor ficient rect if necessary 3 The press ink rollers are 3 Deglaze the rollers glazed 4 The paper is clinging to the 4 Check the paper supply and press blanket clean the blanket 5 The press fountain concen 5 Replace with correct concen tration is too strong tration 6 The press blanket was not 6 Allow the blanket to dry be dry on roll up fore roll up 7 The press blanket is glazed 7 Deglaze the blanket PROBLEM Slow Roll up or Poor Ink Transfer Weak or Uneven Image lose fine lines pinholes in solids Fuzzy or Blurry Image Marks on Plate or Scratched Plates CAUSE l 952 The press fountain concentra tion or ink is incorrect The press ink fountain balance is incorrect The press rolle
107. eStream 15 a halftone device Enter the dot percentages from the densitometer readings In the Warning criteria panel enter the settings used to create the target resolution dot shape and the range of screen frequencies for which this calibration set can be used Q 4 Save the set by clicking the OK button in the Calibration Manager dialog If you click the Cancel button in the Calibration Manager dialog you lose the changes 5 Select a calibration set from the Calibration drop down list in the Page Setup dialog box in order to associate it with a page set up 6 Printa calibrated target to check calibration A single pass new calibration should be accurate to within about 2 For greater accuracy you can do a second calibration iteration by editing the values in the calibration set with the densitometer readings from the calibrated target Edit from calibrated target 7 Repeat this process for each resolution screen and media combination to be calibrated You may need to calibrate only those combinations you use for critical work B 5 HALFTONING AND SCREENING APPENDIX C Halftoning Printware RIPs provide a number of options to control halftone generation Using them appropriately can improve the quality of your image This section gives an overview of halftoning see the RIP manual for more details Halftoning is the process of approximating gray levels or color shades with a pattern of dots In man
108. ea They could be of varying widths and could be vertical lines with fuzzy edges Turn off the Platesetter Open the top cover and raise the marker assembly Inspect the folding mirror through the marker assembly cover aperture using a flashlight See Figure 52 1 Examine the mirror for dust Cleaning the Folding Mirror Using Compressed Air CAUTION Do not remove the Marker Cover at this time Do not touch the mirror surface with your fingers Perform this procedure only if a Dust particles can be seen on the Folding Mirror or b Printed plates have silver vertical streaks or vertical lines with fuzzy edges 1 Hold the compressed air canister upright and direct the nozzle or extension tube toward the mirror surface Do not touch the mirror surface with the extension tube 2 Gently blow the dust away Short quick blasts of air are more effective than continuous spray ing SERVICE MANUAL Getting authorization to remove the Marker Lower Cover On the marker lower cover are two seals which read Warranty Void If Seal Broken Refer to Figure S2 1 In situations where the marker is under warranty the warranty will be void if the marker lower cover is removed without prior authorization Only Printware authorized technicians may remove the Marker lower cover after receiving authorization from Printware Technical Support To obtain authorization to remove the lower cover contact Printware Technical Support by tele phone
109. ectronics eProcessor Imager Assembly The Imager Assembly consists of the following eSpool Assembly eCapstan Roller eL eft and Right Pinch Rollers eCapstan Pinch Roller Stepper Motor Drive System Cutter SERVICE MANUAL Marker This section consists of the following eMarker Assembly Includes Laser Diode Laser Lens Assembly Galvanometer Mirrors SOS and SOT Sensors Power Supply Assembly The power supply assembly consists of the following ePower On Off Switch 20 Amp Circuit Breaker eElectromagnetic Interference EMI Filter ePower Distribution PCA eCooling Fan eMulti output Power Supply eExternal Connectors J1 J5 Cables and Electronics This group of components consist of the following eController PCA eInterface PCA eProcessor PCA eStepper Motor PCA Processor This group of components consist of the following eActivator Tank and Rack With Rollers eStabilizer Tank and Rack With Rollers eDryer eDrive System SERVICE MANUAL CHAPTER 2 MAINTENANCE For physical calibration procedures see the PlateStream Platesetter Installation Guide This chapter identifies which subassemblies within the Platesetter require lubrication details the procedures for lubricating the assemblies and shows the recommended frequency for performing each procedure This chapter also includes information on other preventive maintenance proce dures Performance of lubrication and preventive maintenance procedures 15
110. edia SilverStream Silver halide polyester plates 0 004 to 0 008 thick Integrated Processor Adjustable area based automatic replenishment 36 per minute Two bath design Adjustable developer bath temperature 75 F 95 F 24 C 35 C Adjustable dryer temperature 75 F 140 F 24 C 60 PunchStream Option Integrated punch option for Bacher C2000 or pin bar patterns others available on request Punching repeatability 0 001 25 microns ZAPrip Raster Image Processor ZAPrip HQ Harlequin interpreter RIP Interface Options Novell NetWare Mac AppleShare TCP IP PAP NetBEUI A 3 Physical Dimensions Dimensions 47 hx 29 wx 33 d Weight 500 Ibs Environment Electrical Requirements 220 240V 50 60Hz 4400 VA Temperature 65 F 80 F 18 C 27 C operating 40 F 150 F 40 C 65 C non operating SPECIFICATIONS A 4 APPENDIX B CALIBRATION CALIBRATION Introduction This appendix provides tips for calibrating the PlateStream Following these procedures will provide the best results especially when printing screens Calibration has two major steps I Setting maximum density D in solid black areas by adjusting the laser power II Linearization of the dot percentage transfer curve by calibrating the RIP PlateStream users doing critical screens have found it helpful to calibrate the platesetter weekly or more often if required and replace the processing chemistry every week
111. egarding part applicability please call Customer Service at 651 456 1400 To place your order online please email this form to ceh Q printwareinc com or FAX this form to Printware Inc 651 454 3684 FORM 156 8 24 2000
112. el 2 Replace plate material EN m UJ Check handling techniques when mounting plates and check the uniformity of the plate clamp Adjust the pressure Change to a softer smoother blanket Replace the ink 4 Adjust the moisture control on the press to minimum 5 Replace the ink or add reducer 6 Change Processor chemistry 7 Call for service PROBLEM Toning Specking Background Smeared Images Tails on Charac ters Weak Image on Press m 9 UA m m CAUSE Plate media has abrasions The press ink is emulsified The press fountain solution is contaminated The Platesetter rollers are dirty Platesetter Processor chemistry is weak Plate media defective incom patible Too much press ink The press fountain solution is contaminated The roller pressure on the press 1s incorrect 2 m m IN CASE OF TROUBLE SOLUTION Handle plate media more carefully Change the fountain solution and the ink Change the fountain solution Use only distilled water for preparing solution Clean the rollers Change processor chemistry Change plate media Clean up press and reduce ink Replace the fountain solution Be sure to use distilled or deionized water for preparing the solution Check the stripes pressure be tween the press rollers IN CASE OF TROUBLE
113. embly Number 806701 001 ASSY ACTIVATOR TANK Revision D Find Quantity Component Component Number Used Number Description Parts List Page 1 of 1 001 1 806735 001 TANK ACTIVATOR 002 1 806774 001 FITTING DRAIN 003 1 900291 009 O RING 004 4 901089 003 SCREW STAINLESS TAP FORM 10 24 X 75 005 1 901083 001 FITTING COMPRESSION 007 1 600335 001 HEATER BLANKET 1 00 12 F 3 90 12 s Printware ASSY ACTIVATOR TANK 806701 001 REVISION D Sheet of Printware Confidential Assembly Number 806702 001 ASSY STABILIZER TANK Revision C Find Quantity Component Component Number Used Number Description Parts List Page 1 of 1 001 1 806734 001 TANK STABILIZER 002 1 806774 001 FITTING DRAIN 003 1 900291 009 O RING 004 4 901089 003 SCREW STAINLESS TAP FORM 10 24 X 75 tte 0 NN NN N 0 Xy e g Printware ASSY STABILIZER TANK 806702 001 REVISI N Printware Confidential Sheet of Find Number 001 002 003 004 005 006 007 008 009 011 012 013 014 017 018 019 021 022 023 027 028 Quantity Component Used N N A bl m mom 0 Lm Assembly Number 806708 001 ASSY ELECTRICAL PANEL Number 806736 001 9
114. er Place two DESI PAK bags on the Platesetter crate Roll the Platesetter up the ramp onto the Platesetter crate 3 Support Platesetter off from wheels a Place the 18 by 6 3 4 wood block with lip underneath the bottom front of the imager The frame must rest on the foam b Place another 18 by 6 3 4 wood block underneath the bottom back of the imager The frame must rest on the foam c Place the two 24 by 6 3 4 wood blocks underneath the bottom sides of the imager The frame must rest on the foam d Attach all four wood blocks to the crate by using two wood screws in each block e Replace the front amp side panels and close the top cover 4 Plastic wrap the entire Platesetter Place the foam cap over the Platesetter Place the cardboard shipping sides around the Platesetter Place the ramp inside the foam cap Place the cardboard cover and sides around the Platesetter Place ramp on top of the cardboard cover Strap Platesetter with ramp to crate Make sure the ramp top cover and sides are very secure l 28 INSTALLATION GUIDE This page should be filled out on Installation Serial Numbers and Factory Settings Installation Date Location Serial Numbers Component Serial Model Imager Unit Laser Marker Assy RIP CPU RIP Monitor Setup Cut Length Overlap Length Backup Length Punch off Backup Length Punch on Punch Length Punch on Miniplate Backup Length Image Power Proc
115. er gears Check that the activator and stabilizer transport racks turn freely by hand Lower the drive motor to increase belt tension If motor cannot be moved lower shim the motor bracket away from the frame using the lock wash ers Squealing noise may be the pulley on the end of the worm gear Apply light oil or Teflon spray Motors generally make noise If too loud replace processor drive motor Check to see if the hoses coming from pumps are pinched Replace pumps PROCESSOR SENSOR PROBLEMS Spurious low replenishment level error message Effluent probe not working Processor exit switch does not work SERVICE MANUAL This problem is caused by faulty replenishment level probes l 2 Check the probe connectors Check the cable Place one ohmmeter probe on replenishment probe and the other on the P2 cable Check both replenishment probes for continuity If cable checks out OK replace the PCA Otherwise replace the cable Check probe connector Check cable P3 and PCA see procedures under Spurious low replenishment message Remove the right side end panel Push the exit switch actuator at a 45 angle An indicator light should turn on after a 6 second time delay from the switch clicking on If there is not an audible click when the switch is actuated readjust the switch If it cannot be readjusted replace the switch If the switch actuates but the light doesn t come on replace the s
116. essary dimensions at the physical installation site e g width of doors etc with the Plateset ter dimensions To ensure optimal operation allow clearances of at least 12 30 cm on the left 24 75 cm on the right 30 75 cm in front and 12 30 cm in the rear see Figure I 1 After uncrating the depth of the Platesetter which 1s on casters 15 approximately 33 84 cm If a method for plumbing to remove chemical effluence is required the method must meet local environmen tal codes An optional drain for the chemicals provided with the Platesetter 15 a vinyl flexible hose 6 long 1 1 4 outer diameter and 1 inner diameter Precautions 1 Due to the 500 Ib 227 kg weight of the Platesetter use caution when removing Platesetter from pallet 2 Follow electrostatic discharge ESD protective procedures when connecting cables or working near Platesetter PCAs including Ground yourself by touching the metal chassis of the Platesetter before connecting or disconnecting any cable Use a wrist strap and an antistatic work surface if possible when handling PCAs or other electronic components Always store and transport PCAs in antistatic bags Unpacking and Inspection Keep all the shipping boxes braces crates and packing pieces in case the Platesetter needs to be repackaged 1 Inspect the Platesetter crate for signs of shipping damage Report any damage discovered to the carrier immediately 2 Remove the s
117. essor amp Mini Plate MT Speed 29 PlateStream JC L Platesetter Operator Manual Printware LEADERS IN COMPUTER TO PLATE 700633 Rev B COPYRIGHT NOTICE This manual is copyrighted and all rights are reserved Under copyright law this manual may not be copied by any means or in any form in whole or in part without the written consent of Printware Printware Inc makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties of merchantability or fitness for any particular purpose In addition Printware reserves the right to revise this publication and to make changes from time to time in the content hereof without obligation of Printware to notify any person of such revisions or changes O 1998 by Printware Inc IBM and PC are registered trademarks of International Business Machines Corporation ZipRip ZAPrip and Printstyle are trademarks of Printware Inc Macintosh and AppleTalk are registered trademarks of Apple Computer Inc PostScript is a registered trademark of Adobe Systems Incorporated Futura is a registered trademark of the Fundicion Typografica Neufville SA Times is a registered trademark of the Linotype Company Printstyle is licensed to make use of the PostScript amp page description language copyrighted by Adobe Systems Inc PRINTWARE INC 1270 Eagan Industrial Road St Paul MN 55121 Phone 651 456 1400
118. far enough CAUSE The Guide B sensor is blocked SOLUTION Clear media path See chapter 7 in the section Clearing Media Path Guide B sensor blocked Processor exit sensor blocked Media didn t exit processor OPERATING THE PLATESETTER CAUSE The leading edge of the media was not detected by the Guide B sensor within the expected amount of time SOLUTION Clear media path See chapter 7 in the section Clearing Media Path CAUSE The sensor under cover G 1s blocked SOLUTION Clear media path See chapter 7 in section Clearing Media Path CAUSE The leading edge of the me dia was not detected by the processor exit sensor within the expected amount of time SOLUTION 1 Clear media path See chapter 7 in section Clearing Media Path 2 Calibrate the processor See chap ter 2 in the section Calibrate Menu 4 4 OPERATING THE PLATESETTER CAUSE The Platesetter electronics have detected a problem with one of the power supply voltage levels during power up SOLUTION Turn off the Imager and call for 4 Power out of spec detected ali dd CAUSE A print job was sent to the Platesetter while it was not in the On Line state SOLUTION From the Main Menu on the control panel press 3 to return the Platesetter to the On Line state RIP requesting to image plate Cause The marker unit did not power up cor rectly within the expected time SOLUTION
119. g 15 interrupted the current plate will be imaged the Platesetter will not print the remaining plates the displayed number will return to its selected value If printing is not interrupted then once the specified number of plates have been imaged the displayed value will return to its selected value 2 Choose Pattern This selection sets the pattern The choices are Composite Pttrn Large Black Sqs All White Plate Large White Sqs All Black Plate Light Gray Tone Half Blk Wht Dary Gray Tone Thin Vert Lines Horz Line Res Wide Vert Lines Press Pattern Thin Horiz Screen Wide Horiz Calib Screen Small Black Sqs 4 Pix on Focus Small White Sqs 3 Choose Length Sets the length of the test plate The allowable range is 12 to 22 in processor mode and 2 to 22 in Miniplate modes CONTROL PANEL More Information Menu More Information ESC to exit Run Hardware 8 Punch OFF Calibrate Status Backup Transport Miniplate Cut Length 12 Miniplate Backup ON Guide B Sensor ON ON ESC OFF ENTER 1 Run Hardware Provides access to the Run Hardware menu 2 Calibrate Provides access to the Calibrate menu 3 Status Provides access to the Status menu 4 Backup Feed Transport Turns the capstan motor on and backs up the media six inches This is used to clear media wrapped around the capstan roller see Clearing Media Path in chapter seven To stop capstan motor press
120. hap ter 6 to keep the Platesetter clean and in proper operating condition Be sure all Platesetter covers are completely closed when making plates Once per week or more often if conditions require print a test plate and inspect the print quality If image quality problems are noticed perform the following adjustments Image quality problems may include slight changes in character stroke width image density or background density Refer to your RIP reference guide for instructions on printing a test plate Inspect the plate If image quality problems are found adjust the exposure as described in the next section Adjusting Exposure Laser Intensity See CALIBRATION in Appendix B OPERATING THE PLATESETTER Responding to Control Panel Error Messages This section shows the different error messages which may be displayed on the Platesetter control panel Next to each error message is the cause and the most probable solutions When more than one solution is listed try the first solution first if it does not correct the problem then try the next solution Once the problem is corrected press the ESC key to clear the error message from the display If the solution s listed does not correct the error call your Printware authorized technician to service your Platesetter CAUSE The Platesetter 1s out of media or the me dia not loaded properly SOLUTION See chapter 3 in the section Loading Plate Media o media or not loaded
121. he cause of the plate quality problem is not mirror cleanliness If dust particles or other particles are present on the mirror surfaces then perform the following procedures CAUTION Do not touch the mirror surfaces with your fingers Perform this procedures only if a Dust particles can be seen on the mirror surfaces b Printed plates have silver vertical streaks or vertical lines with fuzzy edges Cleaning the Galvanometer Window Reversing Mirror and Spherical Mirror Using Com pressed Air 1 Hold the compressed air canister upright and direct the nozzle or extension tube toward any mirror surfaces that appear dusty Do not touch any mirror surfaces with the extension tube 2 Gently blow the dust away Short quick blasts of air are more effective than continuous spray ing CAUTION The Reversing Mirror has the most fragile surface Its surface is preferrably cleaned only with compressed air Even gentle rubbing using a soft tissue may destroy its surface coating Perform this procedure only if 1 Dust particles can not be removed from compressed air see above procedure 2 Spots can be seen on the mirror 3 Plates have silver vertical streaks or vertical lines with fuzzy edges 11 SERVICE MANUAL Cleaning the Galvanometer Window Reversing Mirror and Spherical Mirror and Folding Mirror if Compressed Air Does Not Remove the Particles Spots 1 Soak a clean piece of webril wipes with acetone and very carefull
122. he effluent tank is empty before beginning this procedure Place the effluent drain hose from underneath the processor into the effluent tank Drain the processor working tanks by removing the overflow tubes located in the rear of the processor tanks inside the Platesetter Remove cover E Remove guide F by pressing guide towards the back of the Platesetter lift guide from the front of the Platesetter and remove Wash cover E and guide F in warm soapy water and dry using a soft cloth Remove Activator and Stabilizer racks Clean the processor working tanks using warm soapy water and dry with soft cloth Clean Activator and Stabilizer racks using warm soapy water Rotate the rollers and clean them using a soft cloth and warm soapy water Replace the Activator and Stabilizer racks to original positions Replace guides and cover to original position 4 Remove cover G Remove dryer rack by holding the metal edge in the center of the dryer rack lift to clear the two bottom pins and remove Wash cover G and dryer rack in warm soapy water and dry using a soft cloth Replace dryer rack and cover G to original position 5 Close top cover 6 5 IN CASE OF TROUBLE CHAPTER 7 TROUBLESHOOTING Print Quality Troubleshooting PROBLEM CAUSE SOLUTION Scumming ghost 1 The press ink fountain 1 Correct the balance images smudges or balance is incorrect blotches on prints due to poor plate surface 2 The press fountain mix 2 Us
123. he grey level is acceptable NOTE At2400 dpi resolution often times a change of 1 power level will result in a visible change in grey level on the printed patterns B Measuring Solid Black Areas a Runacalibration target or atest plate and measure the density of a solid black area using areflective densitormeter b Set laser power to yield 06 02 below the fully exposed density reading Note that 04 below the fully exposed reading will be more tolerant of variations in media from roll to roll or variations in chemistry temperatures and strengths 08 reading below the fully exposed reading will give you finer text or finer lines and longer press run length c Ifthe density reading is less than optimal D increase the laser power If the reading is greater than optimal reduce the laser power Tip as arough rule of thumb change the laser power by 1 for each 01 density change needed B 3 CALIBRATION II Calibrating the ZAPrip HQ Harlequin RIP The goal of calibrating the RIP is to linearize the transfer curve Figure la shows a calibrated transfer curve and Figure 16 shows a non linear uncalibrated transfer curve E Linear Output E Non Linear Output 10096 E 10096 O O 50 50 0 0 i 0 50 100 0 50 100 REQ UESTED XXIUE REQ UESTED XXIUE Figure la Figure 16 The ZAPrip HQ Harlequin RIP Print Calibration menu allows you to print test strips calibra tion targets C
124. he input spool The choices are A B C D 6 Destination Preset at Processor 7 Display Units Toggles between English and Metric display units QS 3 QUICK START GUIDE ZAPrip HQ Harlequin RIP Setup Imaging Plates 1 Startup the RIP a Connect the RIP to the network and turn it on b Press ctrl alt del on the RIP to log into Windows NT c Log in as Administrator with password printware d Double click on the Navigator icon to launch the RIP 2 Create appropriate page setup s in Page Setup Manager a Ensure that the Negative box is unchecked b Specify plate size and image positioning in the page layout menu c You can specify screens in the Screening menu or leave it at factory defaults Override fre quency and spot function Euclidean Spot Function 100 to 150 Ipi frequency the default Angles Use Harlequin Precision Screening and Rotate screens according to Page Rotation 3 Publish the Page Setup on the network in Input Controller The name associated with the Page Setup in Input Controller will show up on the front end computer Note You may want to specify a name which incorporates resolution plate size or the target press e g Quickmaster2up2400dp1 4 Choose Start Inputs the green traffic light icon from the RIP menu 5 Set up the front end computer to print to the RIP For best results use the Adobe print driver and PlateStream PPD These are provided with the RIP If you do
125. ing A0075 2400 DPI No Media LOW PROC TEMP HIGH EFF LOW REPL PROC ON ESC OFF ENTER 1 Setup Provides access to the Setup menu 2 Test Plate Provides access to the Test Plate menu 3 On Off LINE Sets the Platesetter to either on line or off line The Platesetter must be on line in order to accept print jobs from the RIP The Platesetter cannot be set to On line if there is an error present Advancing the display to any of the sub menus automatically takes the Platesetter off line 2 4 CONTROL PANEL 4 More Information This selection provides access to several menus 5 Load This selection loads the media 6 Cut Fd This selection cuts and feeds the media into the processor for the Miniplate option 7 The bottom three lines lines 6 8 of the Main Menu and Test Plate Menu display the current state of the Platesetter and any error conditions Line 5 displays the marker state only if the marker is not ready to print Line 5 Scan point 10 Current marker state displayed only during a marker error or while the marker is either calibrating or initializing Line 6 On Off Line Idle Current imager state the messages displayed as a single plate is fed through the Platesetter in processor mode are On Off Line Idle Imager ready to start imaging imager and processor are idle except possibly for the last several inches of the last plate exiting the processor On Off Line
126. ing information explains how to prepare the Platesetter for a print job Refer to your host computer operator manual and the RIP operator manual for further detail on connecting and operating these devices with the Platesetter Introduction Before making a plate the Platesetter must be Loaded with the correct type of plate media see Loading Plate Media section in this chapter Connected to the RIP I O panel is located on the top rear of the machine Ready to accept a print job Main Menu displayed on the control panel On Line state no error conditions The integrated processor must be filled to proper levels see Filling the Processor Tanks section in this chapter PREPARING FOR OPERATION Filling the Processor Tanks Overview Fill the processor working tanks and replenishment tanks as needed Follow manufacturer s safety instructions The message LOW REPL will appear on the lower half of the control panel Main Menu when one or both of the replenishment tanks are low on chemistry The message LOW WORKING will appear on the lower half of the control panel Main Menu when one or both of the processor working tanks are low on chemistry The message HIGH EFF will appear on the lower half of the control panel Main Menu when the effluent tanks is full Once per week clean the processor racks Follow the cleaning procedure as described in Chapter 6 Preventive Mainte nance Procedure 1 Remove imager front
127. is 90 tighten adjustment screw If angle A is gt 90 loosen adjustment screw Note 1 full turn ofthe adjustment screw moves the cutter approximately 020 e Tighten the two 9 64 Allen cap screws e After adjustment run two plates and check the second plate for skew Operator Side front of Platesetter L NOTE You must run two plates before checking the results as the first plate will have one cut made at the previous setting Figure 1 5 Checking Cutter Squareness 6 Continue adjusting cutter position and inspecting test plates until the plate is cut square Reattach the rear cover to the Imager unit 1 13 Transport Skew Transport skew results when the media is not feeding through the rollers perpendicular to the capstan roller Before making any other adjustments check the two edge guides to ensure they are securely in place Check the adjustable guide towards the front of the Platesetter 15 should be flush with the media but not so tight that it causes the media to buckle as it moves If you are unsure of whether or not the media is being transported properly open the Platesetter top cover press the load key 5 on the Platesetter control panel Main Menu and watch the media Once you have determined that the edge guides are properly in place follow the procedure below to optimize transport skew 1 To determine whether or not the image is square on the plate print eithe
128. istance is 15 010 enter 010 If the distance is 14 990 enter 010 The length change displayed 15 reset to 0 after pressing enter Print the Grid ps file again and measure the distance between points A and B 4 Repeat steps 1 through 3 until length is within specification 5 At 2400 dpi the manual length is adjustable in 0 002 0 005 cm increments NOTES t is best to make small incremental changes Once you enter a new value for Manual Length Adj it is immediately copied to the battery backup Be careful not to make big adjustments as this could result in corrupt data in the firmware The specification for image length accuracy is 30 003 75 microns I 18 INSTALLATION GUIDE Overlap Adjustment In waste reduction mode the Platesetter scans the leading and trailing edges of the plate causing a black area to appear This black area is the unimageable area of the plate At the leading edge of each plate is a double exposed area visible as a black band where the media was exposed on the trailing edge of the previous plate backed up and re exposed on the leading edge of the current plate If a silver line appears in this lead area then the overlap adjust is set too low 1 From the RIP JOBS directory on the RIP output Leading Edge the Grid 12 ps file 2 To make the adjustments described below from the Main Menu on the control panel Press 4 More Information Press 2 Calibrat
129. ive shaft worm gear The teeth should be engaged at least half way but not be bottoming out The drive shaft can be adjusted by loosening the bearing block screws at each end adjusting the shaft position and tighten block screws 8 Check and tighten hose clamps 9 Check drain and replenishment line for restrictions 10 The drive motor replenisher pump motor and the blower motor do not need to be lubricated 15 SERVICE MANUAL 11 Drive motor assembly removal Remove the wire tray located on the right side of the Platesetter Remove the Platesetter right panel Remove drive motor by unscrewing the three screws holding the drive motor plate to the chassis Disconnect the 2 drive motor leads and unfasten the motor ground wire Take the drive belt off of the drive shaft by rotating the shaft and deflecting the belt off of the pulley 12 Check to verify that the solution is 86 F 30 nominal activator temperature The activator temperature can be changed by adjusting a potentiometer R42 on the PC board Turning the screw clockwise increases the temperature if the potentiometer is blue Turning the screw coun terclockwise increases the temperature if the potentiometer is grey 13 Check to verify that the dryer temperature is 110 F 43 C nominal The dryer temperature can be changed by adjusting a potentiometer R43 on the PC board Turning the screw clockwise increases the temperature if the potentiometer 15 blue Turning
130. l power before servicing the processor 3 Before handling photographic chemicals read the manufacturer s handling procedures including the material safety data sheets Chemicals used in processing are hazardous if handled carelessly Systems Transport When the leading edge of the plate exits the imager the processor transport system also starts Opposed rollers guides and belts will move the media through the activator and stabilizer racks dryer and into the receiver tray Heating The solution in the activator tank is heated by a blanket heater attached to the underside of the tank The heater energizes when power is applied to the processor providing that there is solution in contact with the working tank level sensor The solution temperature is maintained by a working tank temperature sensor Over temperature protection is provided for by means of a thermostat in the blanket heater The dryer heater energizes when imaging starts and de energizes a few seconds after the last plate falls into the receiver The dryer temperature is maintained at the set point by means of a sensor in the dryer chamber Over temperature protection is provided for by a thermostat in the heater assembly Replenishing Replenishment occurs when the media is depressing the switch in the dryer The media travels at 37 inches minute 94 cm minute and the pump can be adjusted to replenish a certain amount for each plate There is a 10 turn adjustment screw on each
131. lace the processor PCA Measure the voltage across the pumps at TS2 2 brown and TS2 3 blue If 220V is present replace pump assembly If 220V isn t present the replace the processor PCA Verify that there is chemistry in the replen ishment tanks Check for leaking hoses Check for air the hoses If there 15 unplug the hose from tank and hold the end over the tank as it pumps until the air is cleared Check for pinched hoses Adjust pump rate see Installation Guide chapter 1 for adjustment procedures Turn heat down on processor PCA by adjusting potentiometer R42 the tempera ture specification is 86 2 F or 30 1 C Replace temperature probe 66 SERVICE MANUAL PROCESSOR ELECTRICAL PROBLEMS cont Processor drive motor does not work 67 Remove both racks and turn on the proces sor If the motor comes on with the racks removed replace one rack at a time If adding a rack causes the motor to stop check the meshing of the gears and the roller end play of that rack Check the worm drive Remove the right side end panel and measure the voltage across motor If voltage reads 220 with motor on but the motor is not spinning replace motor If there is no voltage across the motor check fuse F5 on the PCA If the fuse is good replace the PCA Turn the white motor fan blade by hand If it doesn t turn easily disconnect the drive belt and try again If it still does not tur
132. late 5 The width should be at least 0 050 0 13 cm 6 If a silver line appears increase the value for Overlap Length Adj on the control panel Adjusting Fogging Edge LED optional The Edge Fogging LED option is used only if it is required to image 13 4 34 cm wide media It fogs approximately 0 2 on the operator side of the plate allowing a fully fogged 13 4 plate The intensity of the Edge Fogging LED determines the width of the fogging The Edge Fogging LED 1s located on the operator side guide the Edge Fogging LED intensity adjustment is located on the operator side of the chassis The procedure to adjust the intensity is as follows 1 To enable Edge Fogging from the Main Menu on the control panel Press 4 More Information e Press 8 Edge LED Press ON to turn the Edge Fogging LED ON 2 Run a 13 4 wide plate and check the operator side plate edge to see if it is fully fogged black 3 If thefogging band width is too wide ortoo narrow locate the Edge Fogging LED intensity adjustment see Fig I 14 4 To increase the fogging band width increase the LED intensity by turning the adjustment clockwise To decrease the fogging band turn the adjustment counterclockwise Se Edge Fogging Intensity Adjustment D Figure I 14 Edge Fogging LED intensity adjustment operator side of chassis 20 INSTALLATION GUIDE Adjusting Miniplate optional Backup Length Miniplate
133. ly grounding 2 2 Install AC power conditioner To diagnose intermittent DC problems track platesetter state at time of reboot e g was cutter cutting punch punching processor starting Check fuses in power supply Check voltages at controller PCA Specifications are 5V 0 0 25V 12 0 6V 12V 0 6V and 24V 1 2V Check the I O cable from the RIP Power cycle the Platesetter Reset the RIP Replace the controller PCA SERVICE MANUAL GENERAL IMAGER PROBLEMS cont All silver plates usually indicates the shutter isn t opening properly 1 Check to make sure the correct media is used for printing and the emulsion side is up 2 Check that the shutter spring is in place and operating 3 Verify that the shutter plate isn t hitting the capstan roller To adjust loosen screws on the outside of the transport on the operator and non operator side Adjust the shutter plate to 1 32 to 1 16 0 8 to 1 6 mm from the capstan roller All silver plates Shutter problems 4 Open and close the shutter from the Operator Panel hardware menu Run Hardware ESC to exit Reset Proc 4 1 If the shutter solenoid isn t Start Proc 7 Prime Pump operating check the solenoid with an ohmmeter for a short or open its resistance should be approximately 55 ohms If the ON solenoid is open or shorted replace the solenoid Transport Motor E 1 2 3 OFF ENTER
134. marker assembly from the carton using the C shaped black handle located on the laser end of the marker Place the marker assembly in the Imager by placing the hinge brackets on the hinge shaft not on the brass bushings 8 Slide the marker assembly mounting clip onto the spring loaded brass bushing closest to the Processor 9 Lift the other end of the marker assembly and place it past the brass bushing Slide the brass bushing into place 10 Remove the long 1 wide piece of black tape from the bottom of the marker assembly by gently pulling on the loose end of the tape Remove the C shaped black shipping support by removing the eight screws holding this support 11 To attach the struts to the marker assembly Raise the marker assembly until the ball joints on the outside line up with the strut heads e Firmly push the strut heads onto the ball joints and reattach the caps to lock the struts to the marker assembly 12 Gently lower the marker assembly and lock by pushing the marker lever down until lever is horizontal INSTALLATION GUIDE 13 Remove bubble pack from cables Connect the cables to the marker assembly as follows Connect the grounding strap from the rear of the marker assembly to the Imager unit frame Connect the 10 wire connector to connector J on the printed circuit card PCA assembly located on top of the marker assembly Connect the ribbon cable from the rear I O panel to connector J8 on the PCA
135. mbly Use a 3 32 Allen key for adjustments Operator Side front of Platesetter O To adjust the SOT sensor scan width Figure 1 11 Adjusting Scan Width and Linearity 1 From the RIP output the Grid12 ps file 2 Measure the distance between points A and C see Figure I 11 If the distance between A and C is 212 000 30 48 cm turn the sensor position screw counterclockwise e If the distance between A and C is lt 12 000 30 48 cm turn the SOT screw clockwise One full turn is approximately 0 030 0 08 cm To adjust the SOS sensor linearity Measure the distance between points A and B see Figure I 11 e If the distance between and B is gt 6 15 24 cm turn the sensor position screw counterclockwise e If the distance between A and B is lt 6 15 24 cm turn the SOS screw clockwise One full turn is approximately 0 015 0 04 cm Marker Position Adjustment Physical movement of the marker is not recommended There is however an operator panel adjustment to compensate for slight differences in marker location From the Main Menu on the control panel Press 4 More Information Press 2 Calibrate Press 27 Marker Position xx xx The image can be moved up to 0 05 0 13 cm A positive value moves the image towards the no
136. meter R43 instructions on end panel Recommended temperatures are as follows setting dryer hood temperature too low can result in wet plates too high a temperature can result in media curl Thin paper 100 38 Thin poly or thick paper 110 43 Thick polyester 120 F 49 Heater Element PROC Switch Drive o R42 R43 o Motor ERES Processor PCA lt PCA Screws Blower Processor adjustments right side panel 61 SERVICE MANUAL PROCESSING QUALITY PROBLEMS ARTIFACTS cont Brownish looking plates l Check the activator and in silver areas dryer temperatures 2 Clean the rollers 3 Change processor chemistry 4 Increase the replenishment rate Yellow stabilizer stains l Decrease dryer temperature Clean the rollers Change processor chemistry Dirty roller marks on plates NO 62 SERVICE MANUAL PROCESSOR MECHANICAL PROBLEMS Activator or Stabilizer rollers don t turn Processor drive motor jumping Processor noisy Replenishment pumps noisy 63 Pull the rack out of the platesetter and check that the idler gears are meshing properly with the other gears Adjust gears if necessary Check the end play of rollers which should be approximately 0 010 to 0 020 0 25 to 0 5 mm Check for loose pulley or gear set screws Adjust worm gear drive to better mesh with oth
137. move the spool assembly from the Platesetter 3 Adjust the rear edge guides inside the Platesetter by pulling the edge guide knob up and sliding to the position closest to the plate media width Adjust the front edge guide by loosening the screw and moving the guide all the way to the front 4 Adjust the left hub on the spool shaft to match the edge guide position by squeezing the clip and sliding on shaft Remove the right hub from the shaft by lifting clip and sliding off the shaft Slide media onto shaft Slide the right hub onto shaft by lifting clip and pushing down on spool until spool is tight against media see Figure I 2 5 Place the spool assembly back onto the receptacles in the Platesetter Feed media through rollers and two edge guides Adjust the front edge guide by turning edge guide knob counterclockwise and sliding edge guide until edge guide rests against plate media Lock edge guide by turning knob clockwise Feed the media by hand up to the nip of the capstan roller and engage hold down the load switch Watch so that the feed side of the capstan roller picks up on the media and begins to transport it After the media has fed past the exit side pinch roller release the load switch Manually turn the exit side pinch roller approximately 2 revolutions counterclockwise to remove the loop which may have formed over the capstan roller during the load This last step will help the registration of the first few plates that are output f
138. moving the three screws holding the bracket Slide the belts off of the capstan roller These screws are located underneath the capstan drive assembly 22 SERVICE MANUAL 4 To replace the belts remove the E clip and bearing from the capstan drive assembly Install the new belts in reverse order 5 To replace the motor remove the three screws holding the motor Install in reverse order 6 To replace the capstan roller remove the shutter assembly located above the capstan roller by removing four screws two on each side attached to the Imager and removing two shoulder screws located on solenoid underneath the shutter assembly Remove the following parts from the rear end of the Capstan roller shaft Traction control pulley Traction control belt Jam nut 2 wave washers spacer roller bearing bearing clip removing two hex nuts Remove the following parts from the front end of the capstan roller shaft e pulley removing Allen screw bearing clip removing two hex nuts Access the Capstan roller from the top of the Platesetter Remove the five E clips Remove the roller by sliding the capstan roller toward the front of the frame until the rear of the roller shaft clears the frame Install the new Capstan roller in reverse order Lower the marker and close the top cover Replace the front and rear panels 23 SERVICE MANUAL Cutter Assembly Construction of the Cutter Assembly See Figure
139. n operator side a negative value moves it towards the operator side I 17 INSTALLATION GUIDE Adjusting Image Length This procedure enables you to fine tune the image length setting of the Platesetter to Leading Edge compensate for small mechanical variations in components such as the rollers or drive motors This adjustment is made on the Calibrate Transport Menu on the con trol panel NOTE Before adjusting image length clean all transport rollers inside the Plate setter 1 From the RIP JOBS directory on the RIP output the Grid12 ps file 2 Measure the distance between points A and B see Figure I 12 Use a preci sion steel ruler or digital measuring de vice to check this distance a digital mea suring device is more precise Operator Side front of Platesetter Figure I 12 Adjusting Image Length 3 If the distance between points and B is 215 000 38 10 cm increase the Manual Length Adj value if the distance between A and B 15 15 000 38 10 cm decrease Manual Length Adj To adjust this value From the Main Menu on the control panel press the 4 key More Information e Press 2 Calibrate e Press 1 Calibrate Transport e Press 2 Manual Length Adj Enter the amount to decrease or increase For example if the d
140. n easily replace the motor assembly MEDIA PROBLEMS Media has excessive curl SERVICE MANUAL Check for excessive curl in media Lay a 12 length of material on a flat surface and hold down one end If the other end of the media curls up more than 2 replace media it does not meet the manufacturer s specifi cations Decrease dryer hood temperature potenti ometer R43 instructions on end panel 68 SERVICE MANUAL PRESS RELATED PROBLEMS refer to troubleshooting guides for supplies for most press problems Short run length 69 Check press roller settings Recommended settings for most presses are Form to Plate stripe 1 8 3 mm Plate to Blanket stripe 3 16 5 mm Verify that exposure is set correctly by checking Laser power too high can cause short run lengths Reduce laser power 1 2 3 4 5 6 F 8 CABLE 807150 002 CABLE 803321 001 CABLE 1 BROWN 5 POWER SUPPLY INTEGRATED ASSY 803319 002 2 RED SS PRNGND 20 POWER RED ENG STP 5V 3 ORANGE NC 2 808046 TAB DISERIBUTION ORANGE ENG STP 24V VENT FAN ENG STP GND RED V 45V 1 5 GREEN NC 3 900894 001 PCA ET TN ENG STEPPER oet PLACE cnn SCHEMATIC PAGE 2 anae y DRAWER RED 35V 3 BLACK GND 4 8 GRAY PRN GND 23 807046 001 9 WHITE NC 5 CABLE 803319 002 BLACK GND 6 10 BLACK PRN GND 24 CONTROLLER PCA BROWN PIX ENBL 6 RED CONT 45V BLACK GND 8 522980 001 IR 12 RED PIX
141. n t have the Adobe driver the Linotype 630 driver can be used Note On Windows front ends specify the platesetter as a Local Printer not a Network Printer This allows selection of the correct spool folder at print time 6 Print the Job a On Mac front ends ensure that the appropriate device name has been selected in Chooser and print normally from the application Do not specify screens or resolution in the application b On Windows front ends print to file from the application using the printer set up in step 3 the default printer name is PlateStream when using the PlateStream PPD Select the ZAPrip HQ and the appropriate hot folder Quickmaster2up2400dpi in our example as the destination by browsing Network Neighborhood Select the PlateStream PPD if the application supports PPDs Do not specify screens or resolution in the application QS 4 PlateStream JC L Platesetter Installation Manual Printware LEADERS IN COMPUTER TO PLATE 700632 Rev B INSTALLATION GUIDE Contents Pre Installation Checklist I 2 Confirm Electrical Requirements I 2 Confirm Supply of Recommended Consumables 1 2 Confirm Arrival of the Platesetter I 2 Verify Final Location Precautions I 4 Unpacking and Inspection I 4 Assembling the Platesetter I 5 Assembling the Processor I 6 Installing the Raster Image Processor RIP I 7 Turning On the Platesetter 8 Loading Plate Material I 9 Setting Replenishment Rates I
142. nect the two interface cables between the RIP CPU and the Platesetter The Platesetter I O Panel is located on the top rear of the machine see Figure I 1 INSTALLATION GUIDE Turning On the Platesetter 1 The power switch for the Platesetter is located on the rear of the machine To turn on the Platesetter flip the switch up see Figure I 1 e Each time the Platesetter power switch is turned on the Platesetter performs a series of tests of its internal components If an error message appears on the control panel see the section Responding to Control Panel Error Messages in the PlateStream Operator Manual If the display stops at any initialization point for more than five minutes turn off the Platesetter and call for authorized service The Platesetter boot up procedure takes approximately four minutes If best absolute accuracy 15 re quired allow six hours for the Platesetter to reach operating temperature Once the power up sequence is successfully completed the control panel screen will show the main menu with On Line mode indicated and no error messages displayed Rear I O panel 12 clearance rear 24 clearance rt 12 clearance left pe dii Power Switch di 30 clearance front Figure 1 1 Size and clearances for the Platesetter INSTALLATION GUIDE Loading Plate Media 1 Open the top cover Raise marker by pulling marker lever up until lever stops Lift up marker gently 2 Re
143. ngth of the jobs exceeds an operator selected cut length e g 12 The plate material is then cut and run through the processor MiniPlate cut length can be set from 12 to 18 in the More Information Menu see chapter 2 The gap between jobs in MiniPlate Mode can be eliminated or set to a desired amount in the Calibrate Menu see the Physical Calibration section of the INSTALLATION GUIDE This calibration is enabled in the More Information Menu The CUT Fd key 6 operation will cut and feed into the processor any MiniPlates remaining in the Platesetter The extra material fed to bring the length up to the selected minimum length will be imaged black so as not to pick up ink on the press The word MINT in the lower right corner of the main menu indicates that the Platesetter contains MiniPlates that have not been cut or processed The following digit indicates the number of MiniPlates in the Platesetter and if more than 9 MiniPlates are present the digit will be replaced by a Printware PlateStream 1 5 Load 2 Test Plate 6 Cut Fd 3 On Off Line 4 More Information On Line Transporting A0075 1800 DPI MINI3 ON 4 ESC OFF ENTER CHAPTER 4 OPERATING THE PLATESETTER Making a Plate Controlling Image Quality To maintain optimum print quality use only recommended media and processing chemistry and store all supplies properly Also perform the preventive maintenance procedures detailed in C
144. nsed with water and rotate the gears to free them up Failure to do so can result in gear breakage 3 4 PREPARING FOR OPERATION Loading Plate Media 1 Open the top cover Raise the marker by pulling the marker lever up until lever stops Lift up on the marker gently See Figure 3 1 If you are replacing the roll of plate media the last segment of the previous roll may need to be removed from the platesetter 2 Remove the spool assembly from the Platesetter 3 Adjust the rear edge guide inside the Platesetter by pulling the edge guide knobs up and sliding to the position closest to the plate media width Adjust the front edge guides by loosening the screw and moving the guide all the way to the front 4 Adjust the left hub on the spool shaft to match the edge guide position by squeezing the clip and sliding on shaft Remove the right hub from the shaft by lifting clip and sliding off the shaft Slide media onto shaft Slide the right hub onto shaft by lifting clip and pushing down on spool until spool is tight against media see Figure 3 3 5 Place the spool assembly on the receptacles in the Platesetter Feed media through rollers and two edge guides Adjust the front edge guide by turning edge guide knobs counterclockwise and sliding edge guide until edge guide rests against plate media Lock edge guide by turning knobs clockwise Feed the media by hand up to the nip of the capstan roller and engage hold down the load switch fo
145. ntly lowering the marker and lock by pushing marker lever down until lever is horizontal See Figure S2 1 Galvanometer Laser Assembly a ie EA Reversin Mirror Spherical _ Mirror gt Cover Aperature Folding Lower Cover Figure 52 1 Side View of the Marker SERVICE MANUAL Inspecting and Cleaning Marker Assembly Unit Mirrors CAUTION Marker Assembly mirrors should be inspected and cleaned only if absolutely necessary The marker unit mirrors have a sensitive surface coating and are easily scratched Once a mirror is scratched it is ruined and the entire Marker assembly unit must be returned to Printware for mirror replacement and realignment Overview Under certain conditions it may be necessary to inspect and clean the Marker assembly mirrors Carefully check the condition of the marker Clean only when necessary Normally only the folding mirror the mirror visible through the aperture requires cleaning The laser beam is focused down to a small point when it strikes this mirror and is therefore susceptible to interference from dust or other surface dirt Procedures to Determine if the Mirrors Need Cleaning Ensure that all Platesetter Recommended Periodic Maintenance has been performed Examine the Platesetter output The most likely indications of dirty mirrors are vertical streaks of lighter color than the surrounding ar
146. ol panel to display Power Cycle which means to turn the machine off then back on 29 SERVICE MANUAL CHAPTER 4 REPLACING ELECTRONIC COMPONENTS Introduction Signals output by the RIP are received by the controller PCA mounted on top of the marker In structions and acknowledgments are acted on accordingly The controller PCA controls power to the laser and drive current sent to the galvanometer The data signals sent to the controller PCA cause the circuitry to turn the laser on and off while the galvanometer sweeps the laser light back and forth across the plate surface to selectively expose portions of the plate material passing under the aperture The engine stepper PCA precisely controls the timing of drive signals sent to the various motors within the Imager section to coordinate the feeding imaging and cutting of the plate material The control panel PCA accepts signals from the interface PCA controller PCA and from the hu man operator via the keys on the control panel to control and report Platesetter functions and conditions There are four PCAs and one power supply assembly within the imager half of the Platesetter These are eController PCA eInterface PCA eEngine Stepper PCA ePower Supply Assembly This chapter provides the following information for each PCA elocation evoltages econnector and pin assignments ereplacement instructions This chapter also includes information about the sensors 26
147. on the interface PCA replace the punch solenoid cable assembly order both and have them wired together at the factory before shipment SERVICE MANUAL PUNCH PROBLEMS cont Media gets stuck in punch 1 Clear chips from the system 1 1 If a vacuum cleaner is available attach it to the punch plate plumbing to extract any build up of chips this may be operator or non operator side depending on the chip collec tor configuration Double punch with twisted plate 1 This problem is caused by a hooked edge of the punch pattern snagging the plate 1 1 Adjust punch side to side so that only complete holes are being punched This may require a press adjustment 1 2 Use wider or narrower media so that only complete holes are being punched Overheated compressor 1 Check lubricant level lubricant could have leaked out if the compressor had been tipped When the compressor is running the sight glass should be half full Add Printware part number 901176 002 lubricant up to the half full mark Note Clean the filter in the filler cap with isopropyl alcohol Dry thoroughly before replacing 2 Check for air leaks 58 SERVICE MANUAL PROCESSOR JAMS Plates jamming at 1 processor entrance Check that the processor tanks are fully seated Check that the infeed rollers on the activator rack are turning Check that the media is falling uniformly into the processor from the imager section COVER E GUIDE F PI
148. ortant characteristics of a screen are its spatial resolution referred to as screen frequency and the screen angle as shown in Figure ApC 2 Screen angle Figure ApC 2 Screen Angle HALFTONING AND SCREENING Recommended Settings The best halftone strategy depends on the type of work media resolution and press characteristics but Printware makes the following recommendations for PlateStream computer to plate systems as a starting point Euclidian dots Figure ApC 2 shows circular and elliptical dots but dots can have other shapes These are described in detail in the RIP manual Euclidian dot shapes vary with the screen to minimize perimeter to area ratio which make them a good general purpose dot for black amp white or color printing 133 to 150 line Screens Default Angles Silver halide plate materials support a maximum of 175 line screens but accuracy and calibration become more critical the higher the screen Enhanced AM screens also called supercell screens These screening algorithms allow more precise screen frequencies and angles e g if the application calls for a 150 line 45 screen the separation will be reproduced more exactly with supercell screening Without supercell screening selected the separation screens might be approximated with a variety of different screens and angles causing moir Supercell screening also reduces moir and smooths transi tions in gray levels Enhanced AM screens a
149. pump turn clockwise to increase the flow rate Sensors are in the replenishment tank see figure S2 2 14 SERVICE MANUAL NOTE If the effluent tank accessory is being used and the tank is full the replenisher pumps will not run Controls Prime Pump On the control panel Run Hardware Menu Used to activate the pumps They will run for 5 minutes and then stop Reset Used to clear all systems and prepare the processor section for a new job Quarterly Maintenance 1 Open the top cover See Figure S2 3 and S2 4 Inspect all gears and bearings for wear 2 Make sure that the dryer drive belt is tight If the dryer belt is jumping loose or is sagging it can be tightened by adjusting the bracket on the side rail Loosen the two screws in the bracket and move towards the solution racks to snug up the drive belt Tighten the two screws 3 Make sure that the dryer drive clutch is not slipping or the dryer rollers are rotating slower than the solution rack Tighten the dryer clutch by turning the nut at the end of the shaft clockwise 4 Check to see that there is a slight 0 01 to 0 03 0 03 to 0 08 cm end play in the rack rollers To adjust for this play loosen the set screws in the gears moving the gears on the roller shafts and tighten set screws 5 Check the dryer belts for wear or cracks 6 If there is excessive vibration check for damaged motor mounts 7 Check to see that rack gears are properly seated into the dr
150. r Spool Manager arker Position 00 00 save Imager Setup to RIP Load Imager EU from RIP Edge LED O ON ESC OFF ENTER 1 Calibrate Transport Provides access to the Calibrate Transport menu 2 Calibrate Marker Sets the marker to perform a full calibration the next time the machine is powered up 3 Input Spool Manager Provides access to the Spool Manager menu 4 Marker Position Adqdjusts the side to side image position up to 0 05 0 13 cm Increas ing the value moves the imager away from the operator side decreasing the value moves the imager towards the operator side to accommodate the physical position of the marker 5 Save Imager Setup to RIP Saves the imager setup data to the RIP hard drive 6 Load Imager Setup from RIP Reloads the imager setup data from the RIP hard drive 7 Edge LED Only if 34cm option installed turns on the Edge Fogging LED which exposes approximately 0 2 on the operator side of the plate The Edge LED should normally be OFF for plate widths of 13 3 orless and ON for plate widths more than 13 3 allowing a fully exposed 13 4 plate CONTROL PANEL Calibrate Transport Menu Calibrate Transport ESC to exit h Calibrate Processor Manual Length Cut Length di Overlap Length Backup Length Adj Punch Length Adj j 1 500 Miniplate Backup Len Adj ON ESC OFF ENTER 1 Calibrate Processor Runs
151. r a grid pattern or a solid pattern from the RIP 2 Once the plate has been imaged and processed measure the angle E see Figure I 6 Adjust roller pressure to eliminate transport skew as follows see Figure I 7 e If angle E is 290 tighten the roller pressure on the front operator end of the second pinch roller INSTALLATION GUIDE Leading Edge UJ D T D D O a O JH C D O gt D TL Figure 1 Checking for Transport Skew e If angle E is 90 tighten the roller pressure on the rear end of the second pinch roller Marker Lever Marker Capstan Roller Pinch Roller Q Pinch Roller 4 Cutter lt Optional Punch Media Input Spool Input guide lt Exit guides Figure I 7 Location of the Pinch Rollers 14 INSTALLATION GUIDE Image Skew Leading Edge UJ Image skew is caused by the laser marker assembly being tilted relative to the capstan roller Image skew is present when the material 15 square but the image on the media is measurably skewed 1 Check for image skew by comparing the two di agonal image measurements Measure the distance from point C to point F see Figure 1 8 and compare this to the distance from point D to point E f the two diagonal measurements are equal no image skew is present skip the
152. r approximately 5 seconds Watch so that the feed side of the capstan roller picks up on the media and begins to transport it After the media has fed past the exit side pinch roller release the load switch Manually turn the exit side pinch roller approximately 2 turns counterclockwise to remove the loop which may have formed over the capstan roller during the load This last step will help the registration of the first few plates output from the platesetter after this load sequence as compared with previously processed plates or ones that may be processed later 6 Gently lower the marker and lock down by pushing the marker lever down until the lever is horizontal Close the top cover 7 Set the plate width from the control panel setup menu Load media from the control panel Image one test plate from the control panel Test Plate menu PREPARING FOR OPERATION NOTES Cut off any punched area of plate before reloading to ensure a reliable load Remove leader from daylight load media before loading media Media must be loaded with no tears or wrinkles Media must be reloaded after jams or other fault conditions In this case a message will appear on the operator panel to Reload Media or Manually Reload Media The Optional Edge LED should be ON for plate widths more than 13 3 allowing a fully exposed 13 4 plate see chapter 2 in the section More Information Menu 3 6 PREPARING FOR OPERATION Receptacle
153. re called Harlequin Precision Screens HPS on the ZAPrip HQ Harlequin Xitron RIP 4 PlateStream JC L Platesetter Service Manual Printware LEADERS IN COMPUTER TO PLATE 700634 Rev B CONTENTS Chapter 1 General Information INTTOCUCTION ccccceccccecececcececcceccececcacececscececesceeaesueaeaesneanaees 2 Construction of the 4 Chapter 2 Maintenance Approved L ubDricanis U u dads 6 Cleaning Supplies 6 Platesetter Maintenance 7 Procedures to Raise and Lower the 00000 8 Inspecting and Cleaning Marker Assembly Unit Mirrors 9 Marker Focus Adjustment Procedure 12 Processor DECOM Maori 14 Chapter 3 Component Repair and Replacement Replacing Rollers Belts Motors and Cutter 20 Replacing Marker Unit 25 Chapter 4 Replacing Electronic Components o NOU u Aa ip acm ERUIT aS 26 Controller RR 27 POA u u u uuu uu u u ullu l uuu uu u L usun asa 30 Engine Stepper PCA
154. re page The plate is fed through is imaged the media the imager and into advances to the cutter the integrated The media is cut to a processor specified plate length and punched The plate is developed The finished plates are fixed and dried collected in a basket 14 Figure 1 1 Flowchart of the Platemaker Process GENERAL INFORMATION A s Workstation Job stream character codes pluscommand codes External RIP Filereconfigured commands interpreted Workstation Figure 1 2 Interface Between the Host Computer RIP and PlateStream GENERAL INFORMATION Figure 1 3 illustrates the Platesetter media path It uses a four step photographic process 1 Imaging The laser light beam sweeps across the emulsion side of the plate material as it passes the laser marker unit The data generated by the RIP turns the laser on and off When the laser is turned on the portion of the plate exposed to the laser sweep is imaged black the portions of the media not exposed to the laser remain
155. rease the value for Miniplate Backup Length Adj on the control panel To increase the gap decrease the value Note that Miniplate Backup creates a non imageable area equal to the Backup Length on the trailing edge of each job 6 If necessary follow the procedure for all resolutions to be used with the Miniplate mode Miniplate Backup Length is set independently for each resolution The default Miniplate Backup Length for 2400 DPI is 010 21 INSTALLATION GUIDE Punch optional Alignment and Skew Plates must be punched accurately to align in the press There are two physical calibration adjustments for the punch lateral side to side alignment and skew parallelism to the cut edge Additionally the punch depth longitudinal position can be adjusted in the Operator Panel see Cut Length Backup Length and Overlap Adjustment Adjusting Punch Length in this guide NOTE Before adjusting the punch ensure that the cutter has been adjusted correctly see Physical cali bration Cutter Skew in this guide Because the punch adjustment uses the cut edge as a reference the cutter must be adjusted first Punch Alignment 1 To enable the punch from the Main Menu on the control panel Press 4 More Information e Press 8 Punch e Press ON to turn the punch on 2 Runa test plate with the punch on see Cutter Skew procedure above NOTE Use the intended plate width for these adjustments Lateral alignment
156. remainder of this procedure and go on to the next section 2 To correct image skew adjust the laser marker assembly position bolt Notify Printware s Cus tomer Service Department at 1 800 456 1400 be fore adjusting this bolt to avoid warranty issues To Operator Side front of Platesetter locate this bolt H Stand in front of the Platesetter operator side Figure I 6 No Image Skew facing the Platesetter diagonal D E diagonal C F Open the top cover Look down at the point where the laser marker assembly rests on the Imager module metal frame Locate the laser marker assembly Imager cover locking clamp e The adjustment bolt is to the right of the locking clamp 3 Figure I 8 shows no image skew If the image skew condition shown in Figure 1 9 15 present turn the adjustment screw clockwise to lower the front of the laser marker assembly 4 If the image skew condition shown in Figure 1 10 is present turn the adjustment screw counterclock wise to raise the front of the laser marker assembly 5 After each adjustment close the platesetter top cover Run two test plates and measure the second plate for image skew Continue until the image is square on the plate I 15 INSTALLATION GUIDE Leading Edge UJ UN Open Top Cover Laser Marker Assembly Fixed point Capstan Roller 9 Front Operator Side E Frame Re
157. rom the platesetter after this load sequence as compared with plates processed previous to this load or plates that may be processed later 6 Gently lower the marker and lock by pushing marker lever down until the lever is horizontal Close the top COVer 7 Set the plate width from the control panel setup menu Load media from the control panel Image one test plate from the control panel Test Plate menu NOTES Cut off any punched area of plate before reloading to ensure a reliable load Media must be reloaded after jams or other fault conditions In this case a message will appear on the operator panel to Reload Media or Manually Reload Media e Media must be loaded with no tears or wrinkles EMULSION OUT MEDIA EMULSION IN MEDIA Right Hub Right Hub Left Hub x Media Roll S Position 13 Figure I 2 Loading Plate Media on Spool INSTALLATION GUIDE Setting Replenishment Rates 1 Remove front panel and remove replenishment hoses from the working tanks inside the processor Place the replenishment hoses in measurement containers 2 From the control panel run a test plate that represents the average plate size that will be run on this Platesetter 3 Compare the measured volume to the table outlined below Recommended replenishment rates are as follows Printware SilverStream Activator or Stabilizer 0 37 ounces ft 120 Agfa Setprint Plus Activator or Stabilizer 0 37 oun
158. rs or blanket is glazed Press pressure is insufficient Exposure laser intensity is set too high Platesetter processor chemistry is dirty Laser 15 out of focus The Platesetter rollers are dirty Bad plate material Platesetter processor chemistry is dirty IN CASE OF TROUBLE SOLUTION Check and replace if necessary 2 Check the balance and correct if neces Sary 3 Deglaze the rollers or blanket 4 Check the pressure and adjust if neces Sary 1 Adjust the exposure in the Platesetter Setup menu on the control panel per plate Media Manufacturer s instruc tions 1 Clean processor and replace processor chemistry 2 Call for service 1 Clean the Platesetter rollers 2 Replace the plate material 3 Replace processor chemistry 7 4 IN CASE OF TROUBLE PROBLEM Plugged Images or Excessive Back sround Wrinkled Cracked Plates Plates have Short Press Life CAUSE 1 The exposure is set too high 2 Bad plate material The press plate clamp is improperly set Press pressure is exces sive 2 Press blanket surface 1s too harsh 3 There are abrasive particles in the press ink 4 The press ink fountain balance 15 incorrect 5 The press ink is too tacky ON Platesetter Processor chemistry is depleted 7 Marker out of focus SOLUTION l Adjust the exposure using the Platesetter Setup menu on the control pan
159. rst pinch rollers approx 4 5 lbs 20 N Second pinch rollers 8 14 Ibs 50 N note tensioner on operator side may look tighter due to the traction control on the back of this roller 2 If unable to resolve problem send sample plates to Printware Send four maximum width grid pattern plates We can measure and advise on adjustments 45 OPERATOR PANEL PROBLEMS Operator Panel does not function SERVICE MANUAL 1 The operator panel is an applet on the RIP Check that both the RIP and the Platesetter are plugged in and turned on 2 Check the cable connections between the RIP and the Platesetter Note The machine is designed to beep continuously every 5 seconds if a Job is sent with an unsupported resolution 46 SERVICE MANUAL MARKER GALVANOMETER PROBLEMS For all galvanometer errors recycle the platesetter to clear spurious errors If errors persist use the following steps before replacing the marker assembly Galvo initialization stops at 00 02 03 05 07 10 47 UC Check cables between controller PCA and marker assembly Check controller PCA and power supply voltages Check voltages at power supply Check fuses and replace if necessary Replace Power Supply if necessary Calibrate the marker Replace the controller PCA Replace marker assembly Check galvo connector J14 on the controller PCA 2 Check voltage across R267 or R266 on
160. se top cover NOTE The PROC EXIT sensor is located above the processor PCA See Figure S2 4 Marker Lever Y Marker f Capstan Roller lt Pinch Roller Input guide A Media Input l No Media Sensor lt Exit guide Guide B Sensor 2 Figure 54 2 Front View of the Imager 37 SERVICE MANUAL This page intentionally left blank 38 SERVICE MANUAL CHAPTER 5 TROUBLESHOOTING Introduction This chapter contains procedures for isolating and correcting Platesetter problems in the field NL CAUTION Operations with this symbol require advanced technical training 39 EXPOSURE PROBLEMS Weak image broken type or fine lines pinholes in solids Plugged images or exces sive background SERVICE MANUAL l Verify that exposure 15 set correctly by checking see Operator Guide for details Laser power too high can cause text to break up on press output not the plates 2 Reduce laser power 1 Verify that exposure is set correctly by checking Laser power too low can cause plugged images and excessive background on press output not the plates 2 Increase laser power 5 1 2 3 4 5 7 Setup ESC to exit Image Reading 1 400 DPI Resolution Image Power 40 Media Width 13 12 Spool Pos 13 Media Input Spool A Destination Processor Display
161. the me Uy m controller PCA Calibrate marker Replace controller PCA Check galvo connector J14 on the controller PCA Calibrate the marker Replace the controller PCA Check the laser diode J1 and the safety interlock J7 connectors on the controller PCA Calibrate the marker Replace the controller PCA Check SOS SOT connectors on the controller PCA Check SOT sensor alignment Calibrate the marker Replace controller PCA Replace marker assembly Calibrate the marker Replace the controller PCA SERVICE MANUAL MARKER GALVANOMETER PROBLEMS cont Marker hold error message 1 Turnup fogging circuit clockwise 1 4 turn maximum Note original potentiometer position If resetting does not alleviate problem return to original position 2 Realign SOS and SOT sensors Turn SOS screw 1 full turn clockwise Turn SOT screw 1 full turn counterclockwise Note original screw positions If realigning sensors does not alleviate problem return to original positions 3 Replace marker assembly 48 SERVICE MANUAL GENERAL IMAGER PROBLEMS Platesetter spontaneously reboots Power out of spec message Platesetter is on line but will not start a job 49 DO DES Check AC voltage The specification 15 200 264 Volts 50 60 Hz Protect against AC power glitches 2 Check for correct AC power wiring especial
162. the machine see Figure S4 1 The engine stepper PCA provides power and control signals to the capstan motor and cutter motor Voltages Supplied to the Engine Stepper PCA 24 V DC stepper motor power 5 VDC signal logic 32 SERVICE MANUAL Connector Assignments Not used J2 Not used J3 Not used JA Capstan drive J5 Power in from power supply drawer J6 Not Used J7 Interface PCA J8 Cutter assembly Replacing the Engine Stepper PCA 1 Turn off the Platesetter 2 Remove the rear panel 3 Access the Engine Stepper PCA from the rear of the Platesetter Disconnect the cables from the engine stepper PCA Note the correct orientation of each cable 4 Carefully remove the Engine Stepper PCA by removing the 4 nuts securing the engine stepper PCA to the power supply 5 Install the new PCA in reverse order Replace rear panel 33 SERVICE MANUAL This page intentionally left blank 34 SERVICE MANUAL Power Supply Assembly Location The Power Supply assembly is located in the back of Imager behind the processor section See Figure S4 1 The power supply provides all DC and AC power within the Platesetter The circuit breaker prevents high current from damaging the Platesetter electronics Components The power supply contains a PCA which is responsible for distributing the correct signals within the Platesetter The connectors and other items on the external portion of the power supply drawer
163. the most common type of work to be done The system is driven by the host computer on which the operator composes the text and graphics to be imaged Once the print job has been composed on the host computer it is sent to the RIP where it is prepared for imaging The rasterized file is then sent to the Platesetter where the file is imaged onto a plate Figure 51 1 illustrates the basic system setup Figure S1 2 illustrates the dimensions and external features of the Platesetter SS Workstation Job stream character codes plus command codes External RIP File reconfigured commands interpreted CT Workstation Figure 81 1 Interface Between the Host Computer RIP and PlateStream SERVICE MANUAL Rear I O panel 12 clearance rear 12 clearance left O o 24 clearance rt Power Switch p a v 33 29 2 ud 30 clearance front Figure SI 2 External Features of the PlateStream Platesetter Construction of the Platesetter The five major component areas of the Platesetter are e mager Assembly Marker Power Supply Assembly eCables and El
164. the screw counterclockwise in creases the temperature if the potentiometer 1s grey 14 Printed circuit board removal Remove the wire tray located on the right side of the Platesetter Remove the Platesetter right panel Disconnect all the connectors There are nine quarter turn plastic standoff screws that hold the board on the printed circuit board bracket Rotate these screws 1 4 turn to free the board 15 Dryer heater element removal Remove the wire tray located on the right side of the Platesetter Remove the Platesetter right panel Remove the blower and mounting bracket There are 4 rubber isolators used to mount this assembly Remove the vertical cover panel that forms a part of the dryer plenum The heater is mounted on the inside of this cover 16 SERVICE MANUAL Marker Lever Marker Media Input Spool Capstan Roller Pinch Roller GO Pinch Roller 4 Cutter 4 Optional Punch O Activator Tank Processor Working anks v Processor Rollers C SX S Stabilizer Tank vase D NN ump Figure S2 2 Location of Platesetter Rollers and Replenishment Pump Stabilizer Rack Activator Rack f Rack Drive Gear 17 Dryer Belts Dryer Drive Clutch Dryer Drive Belt Figure S2 3 View of the Processor SERVICE MANUAL Heater Element PROC E Switch
165. the sensor several times while watching the sensor GUIDE B 0 REPLN TANK LOW sensor is not sticking EFFL TANK HIGH PROC TEMP LOW PROC EXIT 3 If Sensor Status does not toggle between 1 and 0 the sensor should be replaced ON ESG OFF ENTER Sensor status menu 55 CUTTER PROBLEMS Cutter won t cycle Cutter won t stop cycling Cutter cycles but doesn t cut 1 SERVICE MANUAL Check and re seat cutter connector Check for loose wires on the cutter switch non operator side of machine See if the cutter motor shaft spins by hand the shaft coming out of the back of the motor Check for any media stuck in cutter Check motor winding resistance normally 10 to 1000 If motor is shorted or open replace the cutter Switch misadjusted 1 1 If switch is open the cutter wheel should turn one third of a revolution 1 2 If switch 1s activated the wheel should turn 2 to 4 revolutions without stopping Switch failed 2 1 Turn the shaft on the back of motor by hand you should be able to hear the switch click 2 2 Check the switch with an ohmmeter in the open and closed positions Remove cutter assembly so cutting blade can be adjusted Lay cutter on a table with cutter blade facing up Turn blade by spinning silver shaft on back of motor by hand clockwise until blade comes down to lowest point in its rotation Loosen set screws on arm with a metric Allen
166. trapping ramp and the top cover from the crate 3 Remove the cardboard sides 4 Attach the ramp to bottom of the crate using the two pegs located on either short side of the crate 5 Remove the plastic wrapping from the unit INSTALLATION GUIDE 6 Remove screws from the four wood blocks mounted to the bottom ofthe crate Remove blocks by slightly lifting the Platesetter 7 Roll the Platesetter down the ramp and on to the floor carefully Assembling the Platesetter 1 Carefully open the carton containing the marker assembly 2 Remove the second cardboard cover from the marker assembly 3 Cut tie strap 4 Identify the front and rear of the marker assembly the front has a warning label and serial number the rear has a grounding strap and welded hinge brackets ROO OSO RO BORO BORO BORO ROTO RO SO TO SOTO SO ROTO TO EOS TOTO SOS OOO OO OOO OO OO OO OOO RO CAUTION Do not set the laser marker assembly down on a flat surface This can damage the resonant galvanometer on the side of the assembly KEKEKE EKK KKK K EK KEK KEK E EK K KK K E K EKK KK K K KK E E E K K EEK K K K KEK E E K K K K K K K KEK EK K K KK K K K K KK EK K K KK K K K K K KK KK KKK K 5 Raise the top cover Remove tie straps and bubble pack from struts Remove the caps on the outside of each strut head 6 Locate the hinge shaft for attaching the marker assembly at the top inside left rear of the Platesetter 7 Have two people lift the
167. troller PCA as follows 29 SERVICE MANUAL CAUTION Follow ESD protective procedures carefully Refer to page 1 1 if neces sary a Remove the gold shield by unscrewing four screws and washers b Disconnect J1 the laser diode connector first and immediately connect the cable to the brown grounding connector located underneath the PCA on the right side of the marker assembly frame See Figure S4 1 This prevents damage to the highly sensitive laser diode c Disconnect all cables from the controller PCA Note the correct orientation of each cable d Unscrew the four standoffs holding the controller PCA Carefully remove the controller PCA from the top of the marker assembly by squeezing the five plastic standoffs holding the controller PCA Note Always transport and store PCAs in anti static bags 3 Install the new PCA in reverse order 4 Recalibrate the marker assembly controller PCA as follows At the main menu move the cursor to position 4 or simply press 4 to access the More Information menu Once inside this menu move the cursor to 2 or simply press 2 to access the Calibrate menu In this menu move the cursor to 3 or simply press 3 to access the Calibrate Marker assembly menu The control panel will display are you sure Pressing ESC exits this menu without chang ing the marker assembly calibration Pressing ENTER will cause the control panel to display Power Cycle which means to turn the machine off
168. u Input Spool Manager ESC to exit 1 Spool A 2 Spool B 3 Spool C 4 Spool D ESC OFF ENTER 1 Spool A Sets the amount of material in spool A up to 280 or 85 m 2 Spool B Sets the amount of material in spool B 3 Spool C Sets the amount of material in spool C 4 Spool D Sets the amount of material in spool D Status Menu Status ESC to exit Sensor Status 2 Current Plate Count 000000 Total Plate Count 000000 Material Used 000000 ESC ENTER 1 Sensor Status This selection provides access to the Sensor Status menu 2 Current Plate Count This selection clears and displays the current plate count Total Plate Count Displays the total number of plates imaged by the Platesetter Material Displays the total number of feet of material run through the Platesetter 2 14 CONTROL PANEL Sensor Status Menu SENSOR STATUS ESC to exit NO MEDIA 0 WRKNG TANKLOW 0 GUIDE B 0 TANK LOW 1 EFFL TANK HIGH 1 PROC TEMP LOW 0 PROC EXIT 0 ON ESG OFF ENTER The Sensor Status menu indicates the current digital status of all Platesetter sensors Explanations of all the sensor indications are shown below This menu is provided primarily for trained techni cian use NO MEDIA Identifies the amount of media in the spool as okay or none A 0 indicates that the media supply is empty 17 indicates th
169. unt 001234 6 Load Imager Setup from RIP M aterial U sed 001200 y 7 Edge LED OFF V J Calibrate Transport iria Manager f Sensor Status E Calibrate Processor i Solak 000 0 WRKGN TANK LOW 0 2 Manual Length Adj 0 000 Sa GUIDEB 0 REPLNTANKLOW 0 Ads oe 52 EFFL TANK HIGH 0 3 Cut Length Adj 1 950 3 Spool C 000 4 Overlap Length Adj 0 725 4 Spool D 000 PROCTEMPLOW 0 5 Backup Length 1 350 PROC EXIT 0 6 Punch Length A dj 1 500 7 Miniplate Backup Len Adj 0 031 J C 4 Figure 2 1 Control Panel Functional Flowchart CONTROL PANEL The Power Up Sequence When the Platesetter power switch is turned on the Platesetter performs a sequence of tests of its internal components While the Platesetter is performing these tests the control panel display will show a series of status messages indicating the progress of the self tests If an error message is displayed correct the error according to the instructions in the Responding to Control Panel Error Messages section in Chapter 4 If the display stops at any initialization point for more than two minutes turn off the Platesetter and call for authorized service When the power sequence is successfully completed the display will show the Main Menu screen Main Menu Printware PlateStream SC 1 Setup 5 Load 2 Test Plate 6 Cut Fd 3 On Off Line 4 More Information On Line Transport
170. up Length are set independently for each resolution Density Dot Calibration See the OPERATOR S GUIDE Appendix B for Density Dot Calibration procedures 25 INSTALLATION GUIDE De Installing the Platesetter These instructions are provided in the event you ever need to repackage the Platesetter 1 Turn off the Platesetter and RIP 2 Disconnect video interface cable from the rear of the Platesetter Packaging the Platesetter A Package the processor section 1 Drain processor Remove the front panel and drain the processor working tanks by removing the overflow tubes located inside the Platesetter to the rear of the processor tanks Catch the effluence in the effluent tank Be careful not to allow the tank to overflow 2 Clean processor a b Remove cover E Remove guide D Press guide towards the front of the Platesetter lift guide from the rear of the Platesetter and remove Remove guide F Press guide towards the rear of the Platesetter lift guide from the front of the Platesetter and remove d Remove Activator and Stabilizer racks C Clean the processor working tanks using warm soapy water Drain and clean the hoses 3 Package inside of processor a co Place 2 plated metal or plastic Styrofoam pieces in the front operator side of the processor working tanks Place 2 non plated Styrofoam pieces in the rear non operator side of the working tanks Repl
171. ware ASSY CAPSTAN DRIVE 804627 002 REVISION N Sheet of 1 Assembly Number 807096 001 ASSY SPOOL 13 Revision E Find Quantity Component Component Number Used Number Description Parts List Page 1 of 1 001 1 806625 002 ASSY SPOOL PLATE ADJ 002 1 806626 002 ASSY SPOOL PLATE FIXED 003 1 807109 001 AXLE SPOOL Printware Confidential Printware ASSY SPOOL 807096 001 REVISION E Sheet 1 of 1 Find Number 001 002 003 004 005 006 007 009 010 011 012 013 014 015 016 017 018 022 023 024 025 026 029 030 031 032 033 034 036 037 038 039 040 041 042 043 044 045 046 047 048 050 Quantity Component Used GO m m Lm sm gt mA m m 3 Do m Lm Assembly Number 808047 001 ASSY PROCESSOR PLATESTREAM SC Number 806743 001 806713 001 900960 005 806733 001 806824 001 900289 003 806786 001 807497 001 806710 001 806714 001 807494 001 806724 001 806727 001 807495 001 900289 004 806792 001 900338 001 806769 001 600333 001 80673 1 001 808049 001 808048 001 806701 001 806702 001 806725 001 900338 002 806793 001 807204 001 600330 001 80683 1 001 806704 001 806705 001 806788 001 806789 001 806790 001 523200 001 806708 001 806703 001 90027 1 003 806739 001 900967 010 806750 001 Revision B Component Description PANEL
172. witch and cable If anew switch and cable does not resolve the problem replace the PCA 64 SERVICE MANUAL PROCESSOR ELECTRICAL PROBLEMS Dryer not heating 65 Check and re seat connectors J4 and J12 on the Processor PCA Check fuses F3 and F4 on the processor PCA Check the Processor PCA 3 Check that dryer heater LEDs A and B are on when the heater should be on 1 e processor on Heater Up To Temperature light not on If LEDs do not go on replace the processor PCA 3 2 If Heater Up To Temperature light 15 on set temperature by adjusting potentiometer R43 Clockwise turns heat up on most PCAs instructions are on the inside of the processor panel 3 3 If Heater Up To Temperature light is always on regardless of the R43 setting replace the thermistor Check heater element 4 Remove dryer heater assembly from processor 4 2 Check heater element resistance with an ohmmeter Normal values are Pin 1 to Pin 2 459 Pin 1 to Pin 3 459 Pin 2 to Pin 3 880 Pin 1 to Pin 4 Open SERVICE MANUAL PROCESSOR ELECTRICAL PROBLEMS cont Replenishment pumps not turning Pumps turning but fluid output is inadequate Activator bath is too hot Check the effluent tank If 1t 1s full the pumps will not come on If the replenishment tanks are low the pump will not come on Check the Check Pump prime light on processor PCA If the light does not come on when the pumps should be on rep
173. wrench Rotate cutter blade shaft on opposite end with pliers until blade is 3 4 of the way through the silver plate on the inside Tighten set screws on arm and test the cutter before reinstalling cutter in machine 56 SERVICE MANUAL PUNCH PROBLEMS Punch does not operate or does not punch all the way through 57 1 At the Operator Panel verify that the punch option is turned on 2 At the regulator on the compressor check the air pressure should be approx 80 psi 2 1 If no air pressure Check that the compressor is plugged in and turned on If you can hear the compressor try adjusting the regulator control on the air compressor Check for leaks around air hosefittings on the punch the punch solenoid and the air compres sor If air pressure is still inadequate replace the compressor 2 2 If air pressure is adequate Check the cable from the punch solenoid to the interface PCA and re seat the cable Check that the air compressor gauge is not stuck Purge the air by opening the valve on the bottom of the glass regulator tube Then let it come back up to 80 psi Turn off the platesetter plug the punch solenoid wire into the shutter connector on the interface PCA Turn the Platesetter power back on and then at the Operator Panel run the shutter to see if the punch operates If so replace the interface PCA If the punch doesn t work when plugged into the shutter connector
174. y halftoning systems the dots can have only one color value but can vary in size to alter the ratio of dot color to background color The simplest use of this technique is approximating gray levels with a pattern of black dots against a white background as illustrated in Figure ApB 1 Here the size of the dots varies to represent different shades of gray You see an area of small dots as a light gray while an area of larger dots each nearly filling its allowed space in the pattern of dots is seen as dark gray More strictly it is not the size of the dots but the resultant ratio of black area to white area that represents the gray value Color shades are approximated with three patterns of dots each in a primary color cyan ma genta and yellow used with or without a fourth pattern of black dots This description of halftoning assumes three patterns in fact the fourth pattern of black dots is almost always used for technical reasons that do not affect the principles of halftoning Within each color separation the size of the dots in relation to their background is proportional to the amount of the primary color in the compos ite shade When the separations are combined typically by overprinting in registration they create the illusion of shades of color The cyan magenta and yellow dots cannot be distinguished when viewed from a distance instead the pattern of color dots appears to be an area of a shade of color Halftoning
175. y and gently wipe the mirror surfaces that have particles attached to them Be sure that only the webril wipes comes in contact with mirror surface Wipe the mirror with a steady slow pace in one direction Use the same method on the galvanometer window Do not clean mirror surfaces or the galvanometer window surface unnecessarily If a surface is clean leave it alone The mirrors and the galvanometer window have thin fragile surface coatings that can be very easily rubbed off Once the surface is rubbed off the mirror is ruined and the entire marker assembly will have to be returned to Printware for repair If spots other than dust particles are present apply only enough pressure to remove these spots It is better to under clean than to over clean a mirror surface If the tissue becomes dirty use a new piece of tissue soaked with acetone 2 Examine each surface with a flashlight to ensure that the entire surface is clean 3 Reinstall the Marker lower cover Do not operate the Platesetter with the lower cover removed Lower the marker and close the top cover Print plates to determine if print quality has improved Marker Focus adjustment Procedure 1 At 2400 DPI image a 12 long 4 pixel on focus test plate from the control panel Test Plate Menu 2 Inspect the plate under an eye loop at least 15 power Observe the cross hairs Note that there are 2 patterns one 15 the negative of the other 3 Open the top imager
176. y disable traction control to see if this solves the problem Noisy capstan motor causes high frequency horizon tal banding down the whole length of plate 3 Check capstan motor mounting 3 2 Replace capstan motor Noisy power supply fan Artifact will be a constant frequency down the page 4 Check fan motor mounting 4 2 Replace power supply fan motor If unable to diagnose the problem send two plate samples to Printware for analysis Wavy vertical lines throughout media or more severe on the non operator side of plate generally low frequency on the order of 10 artifacts per inch Usually a faulty galvanometer Replace marker assembly Wavy high frequency on the order of 100 artifacts per inch vertical lines concentrated in the middle of the plate Usually a faulty controller PCA Well defined straight vertical lines Usually a faulty controller PCA 42 SERVICE MANUAL IMAGE QUALITY PROBLEMS ARTIFACTS cont Fuzzy or Blurry Image 1 Clean processor and replace chemistry see Operator Manual 2 Inspect marker mirrors and clean if necessary see y Chapter 2 NZ 3 Adjust laser focus see Chapter 2 White black or silver streaks 1 Set Density Dot calibration see Installation Guide 2 Increase exposure control panel setup menu NZ 3 Inspect marker mirrors and clean if necessary see Chapter 2 Dirty silver colored spots Clean pinch rollers with D Ink 43 SERVICE MAN

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